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Abrasives Introduction to Abrasives 101
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Introduction to Abrasives provides a comprehensive overview of the use of a variety of abrasive products in manufacturing. Abrasive grains are made of natural or synthetic substances and used in a variety of bonded and coated products. Common grinding techniques rely on the same basic abrasive processes, but the specific kinds of abrasive products used in these processes varies. Abrasives are used in many grinding applications and other industrial processes. Anyone who works in grinding must be knowledgeable about their properties and purpose. After completing this class, users will have a greater understanding of the use of abrasives in manufacturing. This serves as the foundation for understanding more complex grinding topics in order to work with them safely and effectively.
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Abrasives Grinding Processes 201
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Grinding Processes provides a comprehensive overview of the various types of grinding used in modern manufacturing environments. Surface, cylindrical, centerless, and internal grinding processes are commonly used for workpieces of various shapes. Surface grinding is further distinguished by whether the table is rotary or reciprocating, and whether the spindle is vertically or horizontally oriented. Cylindrical grinding is distinguished by workholding, whether center-type or chucking-type. Centerless grinding can be either throughfeed or infeed, and internal grinding can be done on a cylindrical or centerless grinder.A foundational knowledge of the different types of grinding, including how they operate and what types of workpieces they are appropriate for, is necessary for any further learning or training in grinding. This class introduces students to the various types of grinding that they may encounter, describing both machine tools and movements.
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Abrasives Grinding Safety 211
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Grinding Safety provides an overview of safety concerns and precautions for grinding operations. Grinding machines, wheels, and fluids pose a number of safety hazards, so operators must take proper preventative measures. Wheel guards can protect grinding operators from flying shards in the event of wheel breakage. Personal protective equipment, such as safety glasses, provides another barrier between operators and grinding operations, as do automatic safeguards that are built into many modern machine tools. Ensuring that machines, wheels, and fluids are properly used, maintained, and tested also reduces the rate of accidents.Safety is a primary concern for any manufacturing facility. Manufacturers need to ensure that their employees are safe, that their facilities are OSHA compliant, and that they do not lose valuable productivity due to accidents. After taking this class, grinding operators will know safe grinding practices that prevent workplace injury.
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Abrasives Basic Grinding Theory 221
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Basic Grinding Theory provides an overview of the general process of grinding . Grinding occurs at the point of contact between an abrasive wheel and a workpiece. Like any other cutting process, grinding removes material in the form of chips. In order for a wheel to grind properly, its abrasive grains must wear and self-sharpen at a consistent rate. Otherwise, wheel problems such as loading and glazing may occur. Truing and dressing wheels and applying grinding fluids can fix or prevent these issues.An understanding of grinding wheels and processes allows operators to perform grinding operations effectively and recognize and address any grinding wheel problems that may occur. This understanding and recognition will improve the accuracy, precision, and overall success of grinding operations, reducing scrap parts and increasing productivity.
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Abrasives Dressing and Truing 230
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Abrasives Basics of the Surface Grinder 231
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The class Basics of the Surface Grinder provides an overview of the components, considerations, and varieties of the surface grinding machine. Surface grinders are classified by their table types and spindle orientations, and vary in levels of automation. Wheels, workholding devices, and coolant also vary based on the workpiece and grinding operation.Surface grinding is a common operation and is performed when very tight tolerances and surface finishes are required. A surface grinder operator must be familiar with the machine itself, as well as how to select and utilize wheels, workholding, and coolant, in order for the grinding operation to be successful. This foundational knowledge is necessary to reduce scrap, increase quality and production rates, and lower costs.
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Abrasives Basics of the Cylindrical Grinder 232
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Basics of the Cylindrical Grinder provides a comprehensive introduction to different types and components of cylindrical grinding machines. The main methods of cylindrical grinding are plunge grinding and traverse grinding. The main types of cylindrical grinders are plain, universal, automated, and limited-purpose. Grinders may also be categorized by their method of workholding and method of control. Grinding wheels, maintenance, coolant, and grinding variables vary based on the operation.Cylindrical grinding is a common operation performed to finish parts and bring them to tolerance. A cylindrical grinder operator must be familiar with the machine itself, as well as how to select and utilize wheels, workholding, and coolant, in order for the grinding operation to be successful. This foundational knowledge is necessary to reduce scrap, increase quality and production rates, and lower costs.
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Abrasives Basics of the Centerless Grinder 233
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Basics of the Centerless Grinder provides a comprehensive introduction to centerless grinding. Centerless grinding includes both internal and external grinding operations. During centerless grinding, a rotating regulating wheel moves a workpiece, supported by a work rest blade, along a rotating grinding wheel. This abrasive process removes a layer of material from the surface of the workpiece. Its cutting variables include wheel speed, spindle speed, surface or work speed, and feed rate. During throughfeed and endfeed grinding, workpieces move along the length of the grinding wheel, while infeed grinding pushes a shaped workpiece into the grinding wheel.Centerless grinding produces accurate parts with improved surface finish. An operator cannot use a centerless grinder without understanding how the machine functions. After this class, users should be able to describe the general machine components, controls, and basic function of a centerless grinder.
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Abrasives Setup for the Surface Grinder 241
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Setup for the Surface Grinder provides a comprehensive overview of the steps and considerations involved in setting up a surface grinding machine. Setup includes selecting a grinding wheel, testing and preparing the wheel, selecting the correct workholding and/or fixtures for the operation, mounting the workpiece, and setting cutting variables.Setup is integral to achieving an accurate, precise grinding operation. If any step in the setup process is not performed properly, the entire operation may be compromised, leading to a part that is out of tolerance and must be scrapped. An understanding of how to correctly and efficiently set up a surface grinding operation is necessary for increasing part quality and production rates while decreasing scrap.
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Abrasives Setup for the Cylindrical Grinder 242
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Setup for the Cylindrical Grinder provides a comprehensive overview of the steps and considerations involved in setting up a cylindrical grinding machine. Setting up a cylindrical grinding machine includes selecting a grinding wheel, dressing and truing the wheel, selecting the correct workholding and/or fixtures for the operation, mounting the workpiece, setting grinding variables, and ensuring workpiece alignment.Setup is integral to an accurate, precise grinding operation. If any step in the setup process is not performed properly, the entire operation may be compromised, leading to a part that is out of tolerance and must be scrapped. An understanding of how to correctly and efficiently set up a cylindrical grinding operation is necessary for increasing part quality and production rates while decreasing scrap.
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Abrasives Setup for the Centerless Grinder 243
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Setup for the Centerless Grinder explains how to set up a centerless grinder for typical outer diameter (OD) operations. The class explains the necessary setup for the work rest blade and regulating wheel angle of inclination, as well as the methods for selecting and mounting a grinding wheel. The class also explains the proper truing and dressing procedure for both the grinding and regulating wheel.Centerless grinding results in close tolerances but only if the machine is properly set up for the operation. After taking this class, users will be able to describe the steps required to set up a centerless grinder for routine OD grinding of a cylindrical part.
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Abrasives Surface Grinder Operation 251
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The class Surface Grinder Operation provides step-by-step guidelines on how to grind a rectangular workpiece. Grinding each side of a workpiece requires wheel dressing and other preparatory steps, and then roughing and finishing passes. Workpiece sides are numbered from 1 to 6 in order to track which sides must be ground perpendicular or parallel to one another. Some workpieces require special considerations, such as mounting on an angle plate or grinding at an angle.In order to perform successful surface grinding operations, operators must have a solid foundational knowledge of proper grinding methods. This class provides the practical steps and considerations for surface grinding a part from start to finish, which gives operators an understanding of grinding before ever turning on the machine. This will speed up the time it takes for new operators to learn surface grinding, and reduce user errors.
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Abrasives Cylindrical Grinder Operation 252
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Cylindrical Grinder Operation provides a detailed overview of the steps needed to perform the various types of operations possible on a cylindrical grinder. Operations performed on the cylindrical grinder include plunge, traverse, center-type, chucking-type, ID, profile, and taper grinding. Different steps and considerations must be taken in order to perform each type of operation, including setting the grinding variables and using the appropriate machine components and controls.In order to perform successful cylindrical grinding operations, operators must have a solid foundational knowledge of proper grinding methods. This class provides the practical steps and considerations for cylindrical grinding various workpieces from start to finish, which gives operators an understanding of grinding before ever turning on the machine.
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Abrasives Centerless Grinder Operation 253
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Centerless Grinder Operation explains the basic procedures required to properly operate a centerless grinder. To avoid lobing and increase workpiece roundness, a centerless grinder should have the correct workpiece rotational speed, as well as an accurately positioned work rest blade, work guides, and workpiece centerline relative to the wheel centerline.Every centerless grinder has roughly the same structure, and understanding that structure and its required procedures allows operators to grind tightly toleranced parts with accuracy, safety, and speed. After taking this class, the user should be able to describe safe and effective operation of a centerless grinder.
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Abrasives Introduction to Grinding Fluids 261
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Introduction to Grinding Fluids provides an overview of the uses, types, and selection considerations of grinding fluids, or coolants, used in various machining operations. Appropriate grinding fluid use depends on the type of operation, machine tool, and combination of tool and workpiece materials. The basic types of grinding fluids include various combinations of oils, water, chemicals, and additives, and are classified by their contents. The class describes each category of fluid, its optimal uses, benefits, and drawbacks, as well as ideal delivery methods, maintenance, and basic fluid safety and disposal.Selecting, using, and maintaining the appropriate grinding fluid is a key factor in the success of a grinding operation. Proper coolant application can optimize wheel performance and improve finished parts, reducing scrap and tool cost. Additionally, awareness of grinding fluid hazards and maintenance can increase workplace safety and reduce coolant costs.
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Abrasives Abrasive Finishing Processes 271
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Abrasive Finishing Processes provides a comprehensive overview of the various ways abrasives are used to deburr and improve the surface finish of manufactured parts. Abrasive finishing processes use bonded, coated, or loose abrasives to eliminate imperfections and smooth surface finish. Common abrasive processes used for finishing include grinding, honing, lapping, blasting, mass finishing, and more. Finishing processes are extremely important because they increase precision, improve performance, and ensure that parts meet specifications. After taking this class, users will have a better understanding of the different abrasive processes used for finishing as well as their advantages and applications. This knowledge helps prepare users to select and perform finishing processes for various applications.
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Abrasives Grinding Variables 301
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Grinding Variables provides a detailed overview of the different variables involved in any given grinding operation. The parameters of any grinding operation, including tolerances and surface finish, guide the variables of the operation. Variables that can affect the operation's outcome include wheel and workpiece materials, the G-Ratio, the effects of heat and grinding fluid, and the various applicable speeds and feeds.It is crucial that grinding machine operators are aware of how to adjust variables to meet specifications. Adjusting any one variable affects all others, and an incorrect variable can be the difference between a successful grinding operation and a scrapped part. Understanding grinding variables and their impact is essential to reducing manufacturing costs and increasing quality.
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Abrasives Grinding Ferrous Metals 311
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Grinding Ferrous Metals provides an in-depth overview of the considerations involved with grinding various ferrous metal workpiece materials. Ferrous metals’ properties vary widely. This class discusses the properties of cast irons, carbon steel, alloy steels, stainless steels, tool steels, and superalloys, and how those properties affect decisions such as abrasive wheel material, coolant usage, and grinding variables.Ferrous metals are the most commonly ground workpiece material. It is crucial for operators to be familiar not only with the properties of the metals themselves but also with how those properties affect a grinding operation. This class provides operators with knowledge of how to grind ferrous metals successfully, and what potential problems to anticipate and check for within the grinding operation.
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Abrasives Grinding Nonferrous Materials 321
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The class Grinding Nonferrous Materials provides an in-depth overview of the considerations for grinding nonferrous workpiece materials. Nonferrous materials vary widely in their composition and properties, and thus vary in the methods used to grind them. This class discusses the properties of nonferrous metals, including aluminum, nickel, and titanium, as well as nonmetals such as carbide, ceramics, and composites. Properties of workpiece materials affect decisions such as abrasive wheel material and grinding variables.Nonferrous materials pose unique challenges in grinding. It is crucial for operators to be familiar with the properties of the materials themselves and how those properties affect a grinding operation. This class will provide operators with the knowledge necessary to grind nonferrous workpiece materials successfully, and what potential problems to anticipate and check for within the grinding operation.
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Abrasives Grinding Wheel Materials 331
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Grinding Wheel Materials provides a detailed overview of the various abrasive and bond materials used in grinding wheels. The properties of the abrasive grains and bond material are important factors in any grinding operation. Abrasives vary not only in type but also in size, hardness, and friability. Bond material can vary in porosity, strength, and amount. These materials, when combined, can greatly affect material removal rates and surface finish. Grinding Wheel Materials details various abrasive and bond properties, in addition to superabrasives and ANSI nomenclature.When undertaking a grinding operation, the ability to select the correct grinding wheel is crucial to a successful outcome. The wrong grinding wheel can slow production, ruin surface finish, or otherwise fail to create a usable part. A working knowledge of grinding wheel materials will help to ensure high quality, high productivity, and low scrap rates.
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Abrasives Dressing and Truing 341
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Dressing and Truing provides a guide to performing necessary grinding wheel preparations. Prior to using a grinding wheel, operators must visually inspect the wheel and perform a ring test to check for cracks, and then safely mount, true, balance, and dress the wheel. Each process has specific guidelines or goals, and each step is vital to the success of a grinding operation.To perform dressing and truing properly, operators must first understand the wheel preparation process and its overall purpose. Mounting, truing, balancing, and dressing are crucial to the performance of the grinding wheel and to part quality. Improper dressing or truing can lead to poor surface finish, improper tolerances, scrapped parts, and wheel failure.
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Abrasives Grinding Wheel Selection 351
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Grinding Wheel Selection provides a guide on selecting the ideal grinding wheel from a grinding wheel manufacturer's catalog. Grinding wheel manufacturers list various specifications for grinding wheels, including workpiece compatibility, wheel type, wheel dimensions, abrasive material, bond material, grade, grain size, and maximum safe wheel speed. Some specifications, such as wheel type, are selected according to the grinding process. Other aspects of a grinding wheel, such as grain size and wheel structure, depend on workpiece material and the desired grinding results, including tolerance and surface finish.Selecting the most effective and economical grinding wheel requires a detailed knowledge of each aspect of the wheel and an understanding of the specifications needed to meet the requirements of a grinding operation. An incorrect or incompatible grinding wheel can lead to scrapped parts, damaged wheels or machines, and wasted time and money.
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Abrasives Grinding Wheel Geometry 361
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Grinding Wheel Geometry provides an overview of common grinding wheel geometries according to American National Standards Institute (ANSI) standards. ANSI standards provide a common language for grinding wheels, including letter designations for each part of the wheel, as well as guidelines for wheel design and usage. Most grinding wheels are one of eight basic types that are variations of straight and cup wheels. The variations come from different wheel features, such as reliefs and recesses, which make them suitable for grinding different part shapes.Selecting and using the best grinding wheel for an operation requires an understanding of wheel geometry. After taking this class, users should be able to describe common wheel geometries and the applications appropriate for each.
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CNC Introduction to CNC Machines 201
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Intro to CNC Machines provides a comprehensive introduction to computer numerical control (CNC), which uses numerical data to control a machine. CNC machines rely on a system of three linear and three rotational axes in order to calculate the motion and position of machine components and workpieces. A machine control unit controls and guides the movements of the machine tool. This class also describes PTP positioning, which moves to the end position before the tool begins to cut, and continuous path systems that can move a tool along two or more axes at once and cut during the movement. Additionally, closed-loop systems provide feedback, while open-loop systems do not.CNC machines are used to make a variety of products using a number of different processes. With proper training, a human operator can use CNC machines to make accurate parts with decreased risk of error. After taking this class users should be able to describe common components of CNC machine tools and controls.
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CNC History and Definition of CNC 202
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History and Definition of CNC provides a fundamental overview of the development of machine control, from numerical control (NC) to computer numerical control (CNC). NC machines emerged in Industry 2.0 thanks to the invention of the ballscrew and advancements in servomotors and digital tape. Technological developments in Industry 3.0 allowed machines to directly interface with computers, resulting in the first CNC machines. Continuing advancements in digital automation and data exchange are creating new applications for CNC in Industry 4.0.CNC machines are crucial to modern manufacturing and their importance is growing as technology advances. After taking this class, users will be familiar with the origins and defining characteristics of CNC systems. This knowledge will prepare users to learn more about, and ultimately work with, CNC machines.
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CNC Basics of the CNC Lathe 211
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Basics of the CNC Lathe explains the components and functions of both the chucker and bar machine CNC lathe varieties. CNC lathes have spindles that spin workpieces held in chucks or collets. A carriage and cross slide move along ways to position cutting tools against the spinning part. A cutting tool may remove metal from the inside or outside surface. Carbide inserts are the most common cutting tools used in turning operations. Turning centers are also capable of creating holes with the use of drills and reamers. The turret rotates to place the required tool in the cutting position.It is essential for a CNC lathe operator to be familiar with machine basics prior to executing any cutting operation. A trained operator can use a CNC lathe to create precise parts safely and consistently. After taking this class, users should be able to describe the basic functions and general machine components of a CNC lathe.
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CNC Basics of the CNC Mill 212
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Basics of the CNC Mill explains the components and function of CNC mills. A CNC mill produces flat or curved surfaces on square or rectangular workpieces. CNC mills may have a vertical spindle or a horizontal spindle and either their table or cutting tool may move to execute a cutting operation. CNC mills use a variety of tools, which are kept in the toolchanger on a toolholder, to perform different cutting operations. The spindle grabs the toolholder and secures it. On the worktable, vises or fixtures may secure workpieces during machining. The CNC mill can perform multiple operations in the same setup.It is essential for a CNC mill operator to be familiar with machine basics prior to executing any cutting operation. A trained operator can use a CNC mill to create precise parts safely and consistently. After taking this class, users should be able to describe the general machine components of a CNC mill and their basic function.
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CNC Basics of the CNC Swiss-Type Lathe 215
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Basics of the CNC Swiss-Type Lathe describes the basic functions and components of the CNC Swiss-type lathe. CNC Swiss-type lathes are a complex type of lathe with a sliding headstock that feeds bar stock through a guide bushing and toward the cutting tools. The guide bushing is the defining characteristic of the Swiss-type lathe. It provides support at the point of contact between the workpiece and the cutting tool, improving rigidity while reducing workpiece deflection and tool chatter. Additionally, CNC Swiss-type lathes are capable of holding a wide variety of cutting tools.CNC Swiss-type lathes are important pieces of equipment in modern machining due to their ability to machine complex, finished parts with minimal human intervention. After taking this class, users will understand how a CNC Swiss-type lathe differs from a conventional lathe as well as be able to describe the basic functions and general machine components of a CNC Swiss-type lathe.
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CNC CNC Specs for the Mill 220
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CNC Coordinates for the CNC Lathe 221
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Coordinates for the CNC Lathe provides an overview of the coordinates used to program cutting operations on CNC lathes or turning centers. It introduces the systems of both Cartesian and polar coordinates and describes how Cartesian axes are used on a CNC lathe. The class describes both how coordinates are used on blueprints and how they are applied as machine movements. This includes concepts such as incremental vs. absolute coordinates, linear and circular interpolation, machine zero, and program zero.Coordinates and axis movements are at the core of operations for a CNC machine. A foundational knowledge of these topics is necessary to understand how and why parts can be successfully made on the CNC lathe or turning center.
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CNC Coordinates for the CNC Mill 222
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Coordinates for the CNC Mill provides an overview of the coordinates used to program cutting operations on CNC mills or machining centers. It introduces the systems of both Cartesian and polar coordinates and explains the Cartesian axes for vertical and horizontal CNC mills. The class describes how coordinates are used on blueprints and applied as machine movements. This includes concepts such as incremental vs. absolute coordinates, linear and circular interpolation, machine zero, and program zero.Coordinates and axis movements are at the core of operations for a CNC machine. A foundational knowledge of these topics is necessary to understand how and why parts can be successfully made on the CNC mill or machining center.
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CNC CNC Specs for the Lathe 225
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CNC Basics of G Code Programming 231
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Basics of G Code Programming provides a comprehensive introduction to G code programming. Programmers use G codes to create part programs, which direct CNC machines to create a part. Part programs consist of blocks, which contain words that are a combination of a letter address and a numerical value. N codes name or title a program block. G codes describe the operation that the machine will perform. X, Y, and Z codes determine the cutting operation location. F and S codes set the feed and speed, T codes signal the correct cutting tool, and M codes complete other miscellaneous functions.Programmers often rely on computer-assisted programming software to efficiently create part programs. However, to create or edit a part program for a CNC machine, a programmer must understand the different codes in G code programming and what they do. After taking this class, users should be able to describe how G code programming is used to create a part program.
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CNC Introduction to CAD and CAM for Machining 241
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Introduction to CAD and CAM for Machining provides a foundational overview of CAD and CAM systems and how they are used in CNC machining operations. While CAD greatly streamlines the process of part design, CAM ensures successful production by converting the part design into precise machine movements. This class describes CAD design methods, including the different types of part drawings and modeling, and the CAM data conversion process, including how toolpaths and movements are plotted based on design data.Without CAD and CAM, most modern CNC machining would not be possible. They are the first step in CNC part creation, and their correct execution is necessary for a successful part creation process. Understanding how CAD and CAM are used in the CNC process is an essential building block to understanding how successful cutting operations are carried out on CNC machines.
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CNC Control Panel Functions for the CNC Lathe 251
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Control Panel Functions for the CNC Lathe explains how operators use the machine and control panel functions to operate a CNC lathe. Operators use the handle and jog modes to move a turret or machine spindle incrementally or steadily. MDI mode executes isolated lines of programming and memory mode selects and edits existing programs. Before running a program, an operator may choose to execute the program in single block mode to prove it out or select the optional stop or block delete functions. The cycle start button starts the program. Once a program is running, the operator can use the control interface to adjust cutting variables with overrides.To use a CNC lathe, an operator needs to know how to perform important operations using machine panel functions to move machine components and control panel functions to execute programming codes. After taking this class, users should be able to explain the purpose of frequently used controls on the control panel of a CNC lathe.
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CNC Control Panel Functions for the CNC Mill 252
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Control Panel Functions for the CNC Mill explains how operators use the machine and control panel functions to operate a CNC mill. Operators use the handle and jog mode to move mill axes incrementally or steadily. MDI mode executes isolated lines of programming and memory mode selects and edits existing programs. Before running a program, an operator may choose to execute the program in single block mode to prove it out or select the optional stop or block delete functions. The cycle start button starts the program. Once a program is running, the operator can use the machine control unit to adjust speed and feed with an override.To use a CNC mill, an operator needs to know how to perform important operations using machine panel functions to move machine components and control panel functions to execute programming codes. After taking this class, users should be able to explain the purpose of frequently used controls on the control panel of a CNC mill.
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CNC Offsets on the CNC Lathe 261
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Offsets on the CNC Lathe provides explanations of the concept, purpose, and use of offsets on a CNC lathe or turning center. The workshift, geometry, and wear offsets are essential components of any part program. The class first introduces the concepts of offsets, referencing, machine zero, and program zero and then details the axis movements of and programming involved for each type of offset. Additionally, it introduces other offset features, including automatic toolset probes and tool nose radius compensation.Offsets are used in all CNC processes. Since offsets are the most foundational machine tool movements in any part program, a complete understanding of CNC operations requires an equally complete understanding of CNC offsets. After taking this class, users should be able to understand CNC lathe offsets and how to use them.
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CNC Offsets on the CNC Mill 262
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Offsets on the CNC Mill provides an explanation of the concept, purpose, and use of offsets on the CNC mill or machining center and details the movements and programming involved with each type of offset. The workshift, tool length, and cutter radius compensation (CRC) offsets are essential components of any part program. CNC milling may also use additional offset features, including wear offsets and semi-automatic tool compensation.Programming and operating CNC machines requires an understanding of offsets, since offsets form the foundation of all other tool movements. All CNC processes use offsets.
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CNC Creating a Milling Program 290
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CNC Creating a CNC Turning Program 301
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Creating a CNC Turning Program illustrates the process of creating a part program for a CNC lathe. Part programmers use G code programming to perform the different tasks within a part program, from describing the location of a cutting tool to setting the feed and speed. Canned cycles help to shorten the length of part programs.A part programmer needs a thorough understanding of G code programming and how it relates to the axes on a CNC lathe to create a part program that produces accurate parts. After taking this class, users should be able to describe how to write a part program that machines a basic cylindrical part on the CNC lathe.
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CNC Creating a CNC Milling Program 302
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Creating a CNC Milling Program illustrates the process of creating a part program for a CNC mill. Writing the part program is only one step in the process of creating a part. The toolpaths created within a part program depend upon the sequence of operations necessary to machine a part. Different G code programming codes perform the different tasks within the part program, from setting speed and feed to activating rapid positioning. Canned cycles and subprograms help to short the length of part programs.All programs need to be checked by proving out. Programming and how it relates to the axes on a CNC mill are critical for a programmer to successfully create a part program that produces accurate parts. After taking this class, users should be able to describe how to write a part program that machines a basic rectangular part on the CNC mill.
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CNC Canned Cycles 310
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CNC Calculations for Programming the Lathe 311
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The class Calculations for Programming the Lathe provides an in-depth explanation of various calculations necessary to determine tool positions on the lathe or turning center. Trigonometry and circle geometry are used to calculate the toolpaths used in lathe cutting operations. This class introduces the foundational toolpaths and trigonometric equations, including tool nose radius compensation. It then provides a detailed explanation of the calculations needed to determine tool positions for drilling, chamfering, and turning partial and full arcs.An understanding of trigonometry and how it can be applied on the lathe is necessary to perform any lathe operation programming. A knowledge of TNRC, drilling, and arc calculations will allow students to program most basic CNC lathe operations.
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CNC Calculations for Programming the Mill 312
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Calculations for Programming the Mill provides an in-depth explanation of the various calculations necessary to program toolpaths on a CNC mill or machining center for a variety of common operations. Common CNC milling operations covered in this class are face milling, pocket milling, milling full and partial arcs, and holemaking. Important concepts for programming these toolpaths include step-over, approach distance, trigonometry, and boxing routines, as well as some of G codes.Calculations for Programming the Mill details the calculations necessary to program a CNC mill. After taking this class, users will be able to understand and perform most basic CNC mill operations.
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CNC Canned Cycles for the Lathe 321
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Canned Cycles for the Lathe provides an overview of standard canned cycles used on CNC lathes. A canned cycle is a repeatable section of a part program that acts as a programming shortcut for common cutting operations. Canned cycles reduce errors and decrease programming time. CNC controls typically offer standard canned cycles, manufacturer cycles, and customized cycles. CNC lathe and turning center canned cycles include holemaking cycles, simple turning and facing cycles, and the more complex multiple repetitive cycles.Canned cycles are used in a vast majority of part programs. To create, edit, or monitor part programs, programmers and operators must know how canned cycles work and how to program them. After taking this class, users should be able to describe the standard canned cycles available on common CNC lathes and turning centers.
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CNC Canned Cycles for the Mill 322
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Canned Cycles for the Mill provides an overview of the standard canned cycles used on CNC mills. A canned cycle is a repeatable block in a part program that acts as a programming shortcut for common cutting operations. CNC controls typically offer standard canned cycles, manufacturer cycles, and customized cycles. Most CNC mills offer holemaking canned cycles and some also offer milling-specific canned cycles, such as rough facing or pocket milling cycles.Canned cycles are used in a vast majority of part programs. To create, edit, or monitor part programs, part programmers and operators must know how canned cycles work and how to program them. After taking this class, users should be able to describe the standard canned cycles available on common CNC mills and machining centers.
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CNC Controls: Fanuc Fanuc Mill: Control Panel Overview 250
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CNC Controls: Fanuc Fanuc Lathe: Control Panel Overview 255
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CNC Controls: Fanuc Fanuc Mill: Entering Offsets 260
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CNC Controls: Fanuc Fanuc Lathe: Entering Offsets 265
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CNC Controls: Fanuc Fanuc Mill: Locating Program Zero 270
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CNC Controls: Fanuc Fanuc Lathe: Locating Program Zero 275
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CNC Controls: Fanuc Fanuc Mill: Program Execution 280
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CNC Controls: Fanuc Fanuc Lathe: Program Execution 285
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CNC Controls: Fanuc Fanuc Mill: Program Storage 310
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CNC Controls: Fanuc Fanuc Lathe: Program Storage 315
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CNC Controls: Fanuc Fanuc Mill: First Part Runs 320
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CNC Controls: Fanuc Fanuc Lathe: First Part Runs 325
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CNC Controls: Haas Haas NGC: Next Generation Control Panel Overview 101
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Next Generation Control Panel Overview describes the latest control panel from Haas Automation®, Inc. The class identifies the different areas of the control keypad and describes the function of each individual key. Display keys change what information appears on the display screen. Operators use cursor keys to navigate windows, menus, and tables on screen. Mode keys change the operational state of the CNC machine. Operators enter numbers, letters, and special characters using alpha and numeric keys. Override keys temporarily alter feed, speed, and other variables while a part program runs. Jog keys manually control axis motions. Function keys perform a variety of tasks, depending on the mode and display.Gaining a comprehensive understanding of the control panel's different functions will prepare users to successfully perform operations, utilizing the full capabilities of the Next Generation Control.
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CNC Controls: Haas Haas Next Generation and Classic Controls 111
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Haas Next Generation and Classic Controls compares the two versions of control panels from Haas Automation®, Inc. While the two control panels look and function similarly, some key differences separate the Next Generation Control (NGC) and Classic Haas Control (CHC). Operators switching between using CHC and NGC machines must adjust to differences in hardware and software as well as changes to the control keypad and display screen. Additionally, the NGC uses updated cybersecurity features with which operators must familiarize themselves.In order to successfully navigate the operational nuances of the CHC and NGC, it is vital for operators to develop a comprehensive understanding of the differences between the two control panels. After taking this class, users will be able to distinguish between many of the distinct features of the CHC and NGC.
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CNC Controls: Haas Haas NGC: Entering Mill Offsets 201
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Haas NGC: Entering Mill Offsets 201 covers the basics of offsets used on Haas Automation®, Inc.'s Next Generation Control (NGC) mill. Offsets on the NGC mill include work offsets, tool length offsets, tool wear offsets, diameter geometry offsets, and coolant position offsets. The class describes how to access and navigate the offsets menus on the NGC control panel. Additionally, the class explains how milling operators determine and enter offset values both manually and using the Part Zero Set and Tool Offset Measure functions available on the NGC.In order to machine parts successfully, NGC mill operators should understand the concepts of work, tool length, diameter geometry, tool wear, and coolant position offsets and possess basic skills to enter and adjust these offsets before and during a milling operation. The correct application of offsets allows milling operators to avoid machine and workpiece damage, minimize tool wear, and produce parts with the proper tolerance.
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CNC Controls: Haas Haas NGC: Entering Lathe Offsets 202
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Haas NGC: Entering Lathe Offsets 202 addresses concepts and processes for entering offsets on the Haas Next Generation Control (NGC) lathe. Offsets on the NGC lathe include work offsets and a range of tool geometry offsets. Tool geometry offsets for the Haas NGC lathe include tool length, radius, tip direction, and wear offsets. This course describes each individual offset and explains how to navigate the offsets menu and enter offset values into the NGC panel.Performing turning operations on the NGC lathe requires a conceptual understanding of lathe offsets and the ability to enter tool and work offsets using the appropriate steps. Correctly determining and entering tool and work offsets allows operators to improve efficiency by producing more parts within tolerance, minimizing machining errors, and reducing loss due to scrapped or reworked parts.
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CNC Controls: Haas Haas NGC: Locating Program Zero on the Mill 211
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Haas NGC: Locating Part Zero on the Mill describes important considerations for selecting and setting part zero on the Haas Next Generation Control (NGC) mill. Part zero is the origin, or starting point, of a CNC part program and must be accurate in order to successfully perform a machining operation. Machinists use a variety of tools and strategies to locate part zero. Tools and devices used to locate part zero include edge finders, dial test indicators, 3D sensors, and probing systems.After taking this course, machinists will understand effective methods for selecting and setting part zero on various parts and part features. Utilizing best practices for selecting and setting part zero improves machining efficiency and reduces nonproductive time during part setup processes.
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CNC Controls: Haas Haas NGC: Locating Program Zero on the Lathe 212
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Haas NGC: Locating Program Zero on the Lathe describes important concepts related to program zero, or part zero, on the Haas Next Generation Control (NGC) lathe. Part zero is the starting point for all machine operations on the lathe. It is most often located at the center of the finished part face. Lathe operators must determine the most effective approach to locating part zero for each workpiece and operations. Methods for locating part zero vary based on the operator’s approach to setting tool length offsets.After taking this course, operators will be able to distinguish between the different methods for locating part zero and the different factors that determine which approach is best. Operators will also understand the appropriate steps for locating part zero on the Haas NGC lathe with each method. This knowledge will allow them to operate lathes effectively and efficiently.
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CNC Controls: Haas Haas Mill: Classic Control Panel Overview 250
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CNC Controls: Haas Haas Lathe Classic Control Panel Overview 256
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Haas Lathe Classic Control Panel Overview describes the Classic Haas Control (CHC) lathe panel from Haas Automation®, Inc. The class identifies the different areas of the control keypad and describes the function of each individual key. The Classic Haas Control (CHC) lathe control panel has three distinct regions. Manual controls of the Haas lathe, such as the HANDLE, EMERGENCY STOP, and FEED HOLD key, function much like the manual controls of other machines. The display screen shows all relevant information needed during the machining process. The control keypad allows the operator to enter a variety of machine commands. After taking this class, users will have a comprehensive understanding of the control panel's different functions and be able to successfully perform basic operations , including powering up and powering down, checking and activating coolant, sending the turret to machine zero, activating the chip conveyor, and leaving messages.
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CNC Controls: Haas Haas Mill Classic Controls: Entering Offsets 260
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CNC Controls: Haas Haas Lathe Classic Controls: Entering Offsets 265
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CNC Controls: Haas Haas Mill Classic Controls: Locating Program Zero 270
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CNC Controls: Haas Haas Lathe: Locating Program Zero 275
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CNC Controls: Haas Haas Mill: Program Execution 280
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CNC Controls: Haas Haas Lathe: Program Execution 285
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CNC Controls: Haas Haas Mill: Program Storage 310
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CNC Controls: Haas Haas Lathe: Program Storage 315
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CNC Controls: Haas Haas Mill: First Part Runs 320
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CNC Controls: Haas Haas Lathe: First Part Runs 325
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CNC Controls: Mazak Mazak Mill: Control Panel Overview 250
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CNC Controls: Mazak Mazak Lathe: Control Panel Overview 255
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CNC Controls: Mazak Mazak Mill: Safety for the Mill 260
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CNC Controls: Mazak Mazak Lathe: Safety for the Lathe 265
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CNC Controls: Mazak Mazak Mill: Locating Program Zero 270
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CNC Controls: Mazak Mazak Lathe: Locating Program Zero 275
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CNC Controls: Mazak Mazak Mill: Entering Offsets 280
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CNC Controls: Mazak Mazak Lathe: Entering Offsets 285
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CNC Controls: Mazak Creating an EIA/ISO Program for the Mazak Mill 286
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CNC Controls: Mazak Creating an EIA/ISO Program for the Mazak Lathe 287
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CNC Controls: Mazak Creating a Mazatrol Program for the Mill 288
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CNC Controls: Mazak Creating a Mazatrol Program for the Lathe 289
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CNC Controls: Mazak Mazak Mill: Program Execution 290
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This class addresses the steps needed to start, stop, and restart programs on the Mazak mill, along with the steps used to activate a program.
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CNC Controls: Mazak Mazak Lathe: Program Execution 295
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This class addresses the steps needed to start, stop, and restart programs on the Mazak lathe, along with the steps used to activate a program.
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CNC Controls: Mazak Mazak Mill: Program Storage 310
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CNC Controls: Mazak Mazak Lathe: Program Storage 315
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CNC Controls: Mazak Mazak Mill: First Part Runs 320
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CNC Controls: Mazak Mazak Lathe: First Part Runs 325
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Hydraulics and Pneumatics Introduction to Fluid Systems 101
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Introduction to Fluid Systems provides a comprehensive overview of fluid power transmission and fluid power systems. Fluid systems use pressurized fluid to transmit energy. Hydraulic systems use liquids and pneumatic systems use gases. All fluid systems rely on the same basic components for power transmission, but the specific kinds each type of system uses varies. Fluid systems are used in many industrial applications. Anyone who works with fluid systems must be knowledgeable about their purpose and components. After completing this class, users will have a greater understanding of fluid power systems. This serves as the foundation for understanding more complex fluid power topics in order to work with them safely and effectively.
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Hydraulics and Pneumatics The Forces of Fluid Power 201
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The Forces of Fluid Power presents a comprehensive overview of fluid power transmission systems. It offers a broad scope of information, from fluid characteristics and basic energy forms to force multiplication and the effect of fluid flow rate in a system. When pressurized, fluids are able to produce tremendous power with a minimal amount of effort. Maintaining constant fluid flow is essential for any system to work effectively. While the type of fluid in systems differ, the key components of all fluid systems and processes are similar. More importantly, the units of measurement are the same.Without a full understanding of fluid power and the units used to measure key components of a fluid system, a fluid system may not have the proper pressure, volume, force, or fluid flow rate needed to maintain constant fluid flow. After taking the class, users will be able to better recognize how fluids systems function and explain the variables that affect them.
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Hydraulics and Pneumatics Safety for Hydraulics and Pneumatics 211
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"Safety for Hydraulics and Pneumatics" provides a complete overview of the best safety and injury prevention practices for fluid power systems. Fluid power systems rely on the use of highly pressurized liquids and gases. As a result, working with fluid power systems is associated with a variety of hazards, including risk of injection injuries as well as exposure to extreme temperatures and hazardous energy. Several devices and safety procedures can mitigate the potential for accidents and damage to system components.Without a thorough understanding of fluid system safety standards, procedures, and devices, working with pressurized fluids can result in severe burns, poisoning, respiratory damage, intestinal bleeding, and death. After taking "Safety for Hydraulics and Pneumatics, " users will be able recognize how to prevent accidental injury and equipment damage when working with fluid power systems.
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Hydraulics and Pneumatics Introduction to Hydraulic Components 221
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Introduction to Hydraulic Components provides users with an overview of how the active and passive components of a hydraulic system work together to transmit power. The active components of a hydraulic system are the hydraulic pump, control valves, and the actuator. Fluid conductors and fluid storage containers are passive components. Each part of a hydraulic system contributes to the manipulation of pressurized hydraulic fluid in order for the system to perform work.After completing Introduction to Hydraulic Components, users will have an understanding of how the main components of a hydraulic system work together to convert hydraulic energy into mechanical power. Fluid system operators should be knowledgeable about the functions of hydraulic system components and how each part contributes to the success of the hydraulic system.
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Hydraulics and Pneumatics Introduction to Pneumatic Components 231
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Introduction to Pneumatic Components provides a comprehensive overview of pneumatic power and the elements that allow a pneumatic system to perform work. Users will become familiar with the physical laws behind the compression of the pneumatic fluids that power a system and they will gain an understanding of how each unique component impacts the efficiency and effectiveness of the system. Transportation, manufacturing, and construction are just some of the fields that depend on pneumatic systems to perform work. Modern cranes, excavators, and automobile brakes would not be possible without pneumatics. In manufacturing, pneumatic technology is widely used for factory automation, with applications in all steps of product manipulation and processing. After taking this class, users will be able to identify the components that affect each step of a pneumatic system.
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Hydraulics and Pneumatics Introduction to Fluid Conductors 241
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Introduction to Fluid Conductors provides a comprehensive overview of conductors in a fluid system, outlining the potential impact that each conductor has on a specific system. The unique types of conductors have a profound influence on the effectiveness of a fluid system. In general, every conductor offers a tradeoff between flexibility and strength. A fluid conductor must be matched according to the specific needs of a particular system. Without proper fluid conductor selection, leakage and a lack of system inefficiency may occur. Inefficiency will slow production and add excess waste and cost to the process. After taking this class, users will be able to better identify the types of fluid conductors and their specific advantages and disadvantages within a fluid system.
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Hydraulics and Pneumatics Fittings for Fluid Systems 251
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Fittings for Fluid Systems provides a comprehensive overview of the types of fittings used to join or terminate a conductor run, as well as an overview of the maintenance and instillation of fittings. The unique types of fittings have a profound impact on the effectiveness of a pneumatic system. In general, every type of fittings offers something specific in terms of its ability to move, direct, and seal a system. A fitting must be matched to the needs of the size, conductor type and fluid type in use. Without proper fitting selection and maintenance, the pneumatic system will lose efficiency or fail. Loss of efficiency and system failure adds excess waste and cost to the process. After taking this class, users will be able to better identify the types of fittings used in a pneumatic system and how proper selection of a fitting will provide optimal efficiency within a system.
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Hydraulics and Pneumatics Preventive Maintenance for Fluid Systems 261
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Preventive Maintenance for Fluid Systems provides an overview of the benefits of a preventive maintenance program for fluid systems. Contamination in hydraulic or pneumatic fluid is the most common cause of malfunction for hydraulic and pneumatic systems. Preventive maintenance involves using filters or strainers to prevent contamination in the hydraulic fluid. A preventive maintenance program requires system operators to follow routine maintenance schedules regarding seals, conductors, and other system components.A successful preventive maintenance program can help a manufacturing facility reduce downtime, lessen the need for costly repairs, and increase productivity. After taking this class, users will understand the benefits of a preventive maintenance approach for fluid systems.
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Hydraulics and Pneumatics Hydraulic Power Variables 301
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Hydraulic Power Variables provides users with a foundational knowledge of variable factors in hydraulic power and how the variables affect hydraulic systems. Hydraulic power variables are measurable or quantifiable characteristics of a hydraulic system or system component. The two most integral variables are fluid flow and pressure. Additional power variables include speed, horsepower, and torque. Changing any variable impacts the system's operation.After taking Hydraulic Power Variables, users will understand how the variables of a hydraulic system contribute to the manipulation of pressurized fluid in order to transmit power. Understanding the power variables allows hydraulic system operators to predict the performance of a system and select compatible components.
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Hydraulics and Pneumatics Hydraulic Power Sources 302
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Hydraulic Power Sources provides a detailed overview of the most common hydraulic pumps used in hydraulic systems. A hydraulic pump is the power source of a hydraulic system and requires a prime mover, such as a motor or engine, in order to create fluid flow. Hydraulic pumps include positive-displacement pumps such as gear pumps, vane pumps, and piston pumps. A hydraulic power source relies on many components that work together to form a complete hydraulic system.A foundational knowledge of hydraulic pumps is essential to understanding how a hydraulic system functions. After taking this class, users will have a comprehensive understanding of hydraulic pumps and pump ratings, such as flow capacity, pressure, and efficiency.
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Hydraulics and Pneumatics Pneumatic Power Variables 311
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The class Pneumatic Power Variables provides users with a foundational knowledge of pneumatic power and the pneumatic systems that generate it. Pneumatic power variables are measurable or quantifiable characteristics of a pneumatic system or system component. The two most integral variables are fluid flow and pressure. Additional power variables include speed, horsepower, and torque.After taking Pneumatic Power Variables users will understand how the different variables of a system affect the transmission of power in a system. Further they will understand how to evaluate and select the most appropriate and efficient components to power a pneumatic system.
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Hydraulics and Pneumatics Pneumatic Power Sources 312
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Pneumatic Power Sources provides a comprehensive overview of the compressors that allow a pneumatic system to perform work. Users will become familiar with the different types of compressors that may be used in a pneumatic system, as well as the various sources that power these compressors. Users will also gain an understanding of how each unique type of compressor impacts the efficiency and effectiveness of a pneumatic system.Jet engines, heavy construction equipment, and a variety of manufacturing tools would not be possible without compressors. After taking this class, users will be able to identify the different types of compressors that compress air, and the power sources that compressors to perform work.
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Hydraulics and Pneumatics Hydraulic Control Valves 341
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Hydraulic Control Valves describes the three main types of control valves and their functions in a hydraulic system. Control valves control the direction, pressure, and flow rate of fluid as it moves through a hydraulic system. The proper placement of control valves contributes to the overall effectiveness of a hydraulic circuit. Hydraulic system operators use schematic diagrams when studying hydraulic circuits and control valves. Schematic diagrams include symbols for control valves and other system components.Understanding the functions of each type of hydraulic control valve and their proper placement within a hydraulic circuit helps ensure that a hydraulic system produces usable power. After taking this class, users will understand the main types of hydraulic control valves and their various functions. Users will also be able to identify schematic symbols for common control valves.
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Hydraulics and Pneumatics Hydraulic Schematics and Basic Circuit Design 342
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Hydraulics and Pneumatics Pneumatic Control Valves 351
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Pneumatic Control Valves provides an overview of different common pneumatic valves, including regulating, directional control, relief, flow control, and sequence valves. A pneumatic system uses these various types of valves to control the movement, pressure, direction, and flow rate of compressed air as it moves through the system. The types of valves used and their placement in a pneumatic system can maximize the system's potential to do work.Without pneumatic control valves, operators would not be able to assure the optimal air pressure and directional flow that allows the system to operate efficiently and safely. After taking Pneumatic Control Valves users will understand how different pneumatic valves affect the flow of pressurized air in a system. Further they will understand how to evaluate and select the most appropriate components to control pressurized air flow in a pneumatic system.
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Hydraulics and Pneumatics Pneumatic Schematics and Basic Circuit Design 352
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Basic Pneumatic Schematics and Circuit Design provides an overview of different common pneumatic schematic symbols, including air treatment symbols; pressure, flow, and direction valve symbols; and actuator symbols. Further, the class describes an overview of the design principles of a pneumatic circuit and the placement of components within a pneumatic schematic. Without pneumatic circuit design and schematic symbols, designers would not be able to communicate to an engineer the necessary component placement in order to achieve the work for a particular job. After taking Basic Pneumatic Schematics and Circuit Design users will understand basic design principles in a pneumatic circuit schematic and be able to recognize the symbols of basic circuit components.
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Hydraulics and Pneumatics Actuator Applications 361
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Actuator Applications provides a comprehensive overview of the actuators used in industrial fluid power systems. Actuators convert fluid power into mechanical force at the end of a fluid circuit. Fluid power actuators consist of linear actuators, rotary actuators, hydraulic motors, and pneumatic motors. Linear actuators exert linear force, while rotary actuators, hydraulic motors, and pneumatic motors exert rotary force.After taking this class, users will be familiar with the primary types and functions of fluid power actuators. An understanding of actuators helps fluid system operators handle the day-to-day operations of a fluid system.
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Hydraulics and Pneumatics Hydraulic Fluid Selection 371
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Hydraulic Fluid Selection explains the primary functions and properties of the hydraulic fluid within a hydraulic system. Hydraulic fluid must lubricate components, seal clearances, dissipate heat, and transfer power as it flows through a fluid system. This class gives an overview of the types of hydraulic fluid used in industrial and mobile hydraulic systems. Hydraulic fluid is either petroleum-based oil, water-based, or synthetic. Selecting the hydraulic fluid for an application requires consideration of fluid properties and characteristics, such as the fluid's viscosity and whether it is compatible with system components.After taking this class, users will be familiar with common hydraulic fluids and their applications. A knowledge of hydraulic fluid helps prevent maintenance issues arising from fluid incompatibility and prevents downtime. Hydraulic system operators and technicians should be aware of hydraulic fluid selection guidelines.
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Hydraulics and Pneumatics Contamination and Filter Selection 381
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Contamination and Filter Selection describes common contaminants that may affect a fluid system. Contaminants include solid particles, liquids, and energy. Hydraulic and pneumatic systems are both subject to contamination, but hydraulic systems are more susceptible due to their higher operating pressures and recirculation of fluid. Filters are used in a fluid system to clean fluid and control contamination. Filters are selected based on the target cleanliness for a system or component.A knowledge of the filter selection process helps fluid system operators to determine the most efficient and appropriate filter to use. Being aware of common contaminants that may damage a fluid system helps machine operators prevent malfunctions and reduces downtime.
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Hydraulics and Pneumatics Hydraulic Principles and System Design 391
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Hydraulic Principles and System Design provides an overview of the process used to design a basic hydraulic system. Hydraulic system design requires familiarity with the components of a hydraulic system and the various fluid power formulas used when sizing hydraulic components. Engineers use fluid power formulas to solve for variables such as horsepower, flow rate, and pressure.After taking this class, users will be familiar with the fluid power formulas used when designing a hydraulic system. A knowledge of fluid power formulas and hydraulic system design helps employees to correctly size components and perform troubleshooting.
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Inspection Basic Measurement 101
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The class Basic Measurement offers an overview of common gaging and variable inspection tools and methods. Variable inspection takes a specific measurement using common devices such as calipers and micrometers. The sensitivity of the instrument must be greater than the measurement being taken. Both calipers and micrometers are read by finding the alignments in lines on the devices. Gages, such as gage blocks, plug gages, ring gages, and thread gages, reveal whether a dimension is acceptable or unacceptable without a specific quantity. All inspection devices should be properly mastered and maintained to retain accuracy. One of the fundamental activities of any shop is the measurement of part features. Consistent measurement and inspection maintains standardization and ensures that out-of-tolerance parts do not reach customers. After taking this class, users should be able to describe the use and care of common inspection instruments and gages used in the production environment.
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Inspection Calibration Fundamentals 111
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The class Calibration Fundamentals provides a basic introduction to the importance of calibrating measuring instruments. Calibration determines the accuracy of measuring instruments by comparing its value to a higher-level measurement standard, usually a working standard gage block. Measurement standards follow a hierarchy consisting of primary, secondary, and working standards. Traceability links these standards together. Measurement uncertainty estimates the accuracy of a measurement. It is the range in which the true value of a measurement is expected to lie. High-accuracy parts require tight tolerances. Tighter tolerances require higher-accuracy measuring instruments. While uncertainty and error exists in every measurement, careful calibration can help to minimize inaccuracy when inspecting parts with measuring instruments. After taking this class, users should be able to explain how calibration and traceability impact the use and care of inspection devices.
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Inspection Basics of Tolerance 121
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Basics of Tolerance provides a comprehensive overview on part tolerancing, including different types of tolerances and the relationship between tolerances and part dimensions. Every manufactured part must meet certain specifications. Tolerances describe the range of acceptable measurements in which a part can still perform its intended function. Tolerance ranges typically describe a linear measurement. Surface texture can require a certain tolerance as well. Tolerances attempt to balance the use of a product with the cost required to produce that product.Improper tolerancing can result in parts that do not function in the way they were intended or parts produced with dimensions that are more precise than necessary, adding unwanted cost to production. After the class, users will be able to describe common methods used for part tolerancing, as well as the impact tolerances have on part production and quality.
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Inspection Blueprint Reading 131
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The class Blueprint Reading provides a thorough understanding of blueprints and how to read them. Blueprints are documents that contain three major elements: the drawing, dimensions, and notes. The drawing illustrates the views of the part necessary to show its features. Together, the extension and dimension lines on the drawing indicate dimensions and specific tolerance information of each feature. The notes contain administrative and global information about the part. A blueprint contains all instructions and requirements necessary to manufacture and inspect a part.An understanding of how to read a blueprint is critical to manufacture and inspect parts to accurate specifications. Accurate blueprint creation helps to ensure that finished parts will function in a way that meets the original intent. After taking this class, users should be able to read a basic blueprint and determine the critical features on a part that need to be measured.
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Inspection Hole Standards and Inspection 141
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The class Hole Standards and Inspection provides a comprehensive introduction to hole inspection using contact instruments. Hole inspection ensures that a hole will meet its proper job specifications, including fit, diameter, roundness, and condition. Gaging instruments, like pin and plug gages, determine fit. Variable instruments determine size and must make three points of contact to find out-of-round conditions. Variable instruments may be mechanical, electronic, optical, or pneumatic. More complex handheld devices include telescoping gages, split-ball gages, calipers, inside micrometers, and bore gages. Job specifications, environmental concerns, and economic issues all determine which hole inspection device to use. Choosing the wrong tool could result in an out-of-tolerance hole passing inspection. After taking this class, users should be able to explain how to measure common hole features with plug gages, pin gages, and calipers and verify they are within tolerance.
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Inspection Thread Standards and Inspection 151
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Thread Standards and Inspection explains the various parts of threads and how to inspect them. Manufacturers inspect threads according to unified or ISO standards or using System 21, System 22, and System 23. Several features must be checked to make sure that threads meet specifications. Gaging inspection tools, or go/no-go gages, simply determine whether or not a part will fit. Variable thread inspection tools determine whether a thread falls within a specified tolerance range. Thread type and specifications affect the tools used to inspect threads.Understanding the various components and classifications used to identify threads is critical for accurate inspection. After the class, the user will be able to explain how to measure common threaded features with internal and external thread gages and verify the features are within tolerance.
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Inspection Surface Texture and Inspection 201
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The class Surface Texture and Inspection provides information on surface finish and methods involved for its inspection. The surface finish achieved by a machining process determines how well a surface performs its given function. Surface inspection compares the specified nominal surface and real surface to find the measured surface. Measurement can be completed by comparison, direct measurement with a stylus-type instrument, or noncontact methods. A real surface contains irregularities (flaws, roughness, waviness, and lay) that make up its surface texture. Roughness is the most common irregularity used to inspect surfaces. The desired finish of a surface changes how precisely a part must be machined. Inspecting for surface roughness reduces the cost of surface finish by allowing companies to produce parts to customer specifications. After the class, users should be able to describe commonly used methods for tolerancing a part's surface roughness in a production environment.
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Inspection Nondestructive Testing 211
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Nondestructive Testing 211 provides an overview of nondestructive testing and its six most common methods. Nondestructive testing (NDT) is the process of evaluating the quality and integrity of a manufactured part without harming its usability. There are six common NDT methods: visual testing, liquid penetrant testing, magnetic particle testing, eddy current testing, radiographic testing, and ultrasonic testing. Each method requires a certified technician choosing appropriate variables, operating the equipment, and interpreting results.Despite NDT's many advantages, no one NDT method is capable of finding all types of flaws and defects in every type of part. As a result, manufacturers and inspection personnel must have a proper understanding of NDT and its most common methods in order to ensure it is used both effectively and reliably. After taking this class, users will be able to better understand NDT, its six most common methods, and the appropriate applications of each.
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Inspection Measuring System Analysis 300
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Inspection Introduction to GD&T 301
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Introduction to GD&T provides a basic introduction to the symbols and terminology of geometric dimensioning and tolerancing, or GD&T. GD&T is an international design standard that uses 14 standard geometric tolerances to control the shape of features. GD&T emphasizes the fit, form, and function of a part by comparing the physical features of the part to the theoretical datums specified in the design instructions. Every part feature is described by a series of symbols organized in the feature control frame. Because GD&T's tolerance zones more accurately follow the shape of a feature, emphasizing the relationship between features, blueprints commonly utilize GD&T to describe parts. To fully understand a blueprint, it is necessary to know the GD&T symbols and their meaning. After taking this class, users will better understand the symbols commonly used in a GD&T print.
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Inspection Major Rules of GD&T 311
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Major Rules of GD&T provides an overview of the rules and concepts of geometric dimensioning and tolerancing, or GD&T. The major rules include Rule #1, or the Envelope Principle, which specifies how size controls form, Rule #2, or RFS and RMB defaults, and the 3-2-1 Rule, which defines the minimum number of points of contact in the datum reference frame. In addition to these major rules, other concepts described are bonus tolerances, virtual and resultant conditions, and the components of the datum reference frame. GD&T functions as a complex language used in blueprints to convey necessary information about a part. GD&T standards offer specific guidelines for part features, including projected tolerance zones, radii, controlled radii, tapers, threads, and gears. To accurately read a GD&T print, users must understand its many rules and principles. After taking this class, users should be able to explain key GD&T concepts and approaches for part inspection.
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Inspection GD&T Applications 312
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Geometric Dimensioning & Tolerancing (GD&T) is a language used in part drawings and prints to convey all necessary information about a part. GD&T Applications provides an overview of how to interpret a part's tolerances with GD&T. Users must be familiar with basic symbols, rules, and principles of GD&T, including the datum system, to properly interpret tolerances. It is also important to understand how the assembly of a part influences its design, and how the accurate interpretation of tolerances informs inspection of a part.After taking the class, users will better understand how to interpret a feature control frame for various form, profile, orientation, location, and runout tolerances, and how to apply those tolerances to part creation and inspection.
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Inspection Inspecting a Prismatic Part 321
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Inspecting a Prismatic Part explains the measurements, methods, and inspection tools necessary to confirm that a prismatic part meets its specifications. A number of instruments have the right amount of sensitivity required to inspect most prismatic parts, but a CMM is often the most accurate. Inspection starts by measuring each size dimension in two ways: the cross-sectional dimension, or actual local size, and, sometimes, the actual mating envelope (AME). Prismatic parts are also routinely inspected for certain geometric tolerances, including straightness, flatness, profile of a line, profile of a surface, angularity, perpendicularity, parallelism, and position.The ways in which a part must be inspected is based largely upon its shape, so proper inspection of a prismatic part requires an understanding of its basic dimensions and tolerances. After taking this class, users will be able to describe best practices for inspecting the complete layout of a prismatic part.
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Inspection Inspecting a Cylindrical Part 331
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Inspecting a Cylindrical Part explains the measurements, methods, and inspection tools necessary to confirm that a cylindrical part meets its specifications. A number of instruments have the right amount of sensitivity required to inspect most cylindrical parts, but a CMM is often the most accurate. Inspection starts by measuring each size dimension in two ways: the cross-sectional dimension, or actual local size, at one location along the part and the actual mating envelope (AME) along the part’s entire length. Cylindrical parts are also routinely inspected for certain geometric tolerances.The ways in which a part must be inspected is based largely upon its shape. Thus proper inspection of a cylindrical part requires an understanding of its basic dimensions and tolerances. After the class users should be able to describe best practices for inspecting the complete layout of a cylindrical part.
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Inspection Advanced Hole Inspection 341
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Advanced Hole Inspection provides an overview of hole inspection using noncontact instruments. Holes that require a specific type of fit, either clearance, interference, or transition, also require a higher degree of accuracy. Noncontact hole inspection devices provide this, as well as an ability to measure fragile parts and high volumes of parts. These more sophisticated variable hole inspection devices include coordinate measuring machines, measuring microscopes, optical comparators, borescopes, laser systems, and air gages.Job specifications, part dimensions, and feature size all determine which hole inspection device to use on holes requiring a certain fit. Choosing a tool without a high degree of accuracy could result in an out-of-tolerance hole passing inspection. After taking this class, users will be able to describe advanced methods for inspecting hole dimensions and geometric features in a lab setting.
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Inspection Inspecting with Optical Comparators 351
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Inspecting with Optical Comparators provides an overview of the optical comparator, which uses optics to project an enlarged, two-dimensional shadow of a part onto a glass screen for measurement of its length, width, and surface. Simple optics display the part upside down and backwards. Corrected optics display the part right side up and backwards. Fully corrected optics yield an image identical to the part orientation. Regardless of type and complexity, all optical comparators measure by comparison, screen rotation, and motion.If optical comparators are properly maintained, measurement error is the result of the operator. By understanding the components and measurement methods of the optical comparator, operators can avoid unwanted variation. Variation in measurement can lead to faulty parts passing inspection and reaching consumers. After completing the class, users will be able to describe best practices for using the optical comparator to inspect parts.
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Inspection Inspecting with CMMs 361
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Inspecting with CMMs provides a comprehensive overview of the functions and mechanics of the coordinate measuring machine, or CMM. A CMM’s probe contacts the various features on a workpiece and records their Cartesian coordinate locations with software. CMMs measure using either contact or noncontact methods and can be used in a lab or on the production floor. CMMs use either manual operation, joystick, or DCC to guide components.As long as the operator is trained in its use, the CMM provides high accuracy measurements with minimum human influence in a very short amount of time. This allows the operator to respond to machining errors and reduce scrap. After this class, users should be able to describe best practices for using the CMM to inspect parts.
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Inspection Introduction to CMM Arms 362
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Introduction to CMM Arms provides an overview of the components and functions of a portable coordinate measuring machine arm, or CMM arm. Portable CMM arms are used to measure workpiece features and record their coordinate locations with software. CMM arms measure using either contact or noncontact methods and can be used in most environments on the production floor.CMM arms are used for many applications in manufacturing, including inspection, rapid prototyping, and reverse engineering processes. After taking this class, users will be able to describe CMM arms and best practices for using them.
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Inspection Introduction to Laser Trackers 365
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Introduction to Laser Trackers provides an overview of the components, functions, and applications of laser trackers. A laser tracker is a type of portable coordinate measuring machine (CMM) that is used to measure large-scale workpiece features and record their geometry. Laser trackers gather measurements by sending a laser beam to a retroreflective target and can be used in most environments on the production floor. Additionally, operators use handheld probes to measure out-of-sight areas and record 6DoF measurements.Laser trackers are used for many applications in manufacturing, including inspection, GD&T analysis, and reverse engineering processes. After taking this class, users will be able to describe laser trackers and how they function.
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Inspection Calibration and Documentation 371
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Calibration and Documentation details the calibration of measuring instruments and its necessary documentation. Calibration should occur at regular intervals. Companies should have a written document that defines their calibration procedures. Calibration records and reports ensure that traceability is intact. This documentation proves that measurements are accurate. The required accuracy of the measuring instrument determines in-house or outside calibration. Without traceability, there is no way to ensure that a measurement made by an inspection device is accurate.Calibration and documentation reduce waste and increase part accuracy, which in turn increases customer satisfaction. After taking the class, users should be able to describe best practices for instrument and gage calibration, along with correct documentation of calibration efforts.
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Inspection Structured Light 3D Scanners 375
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Structured Light 3D Scanners provides an overview of the components, functions, and applications of structured light scanners. A structured light scanner is a type of 3D optical measuring device used to record an object's geometry. Structured light scanners gather measurements by projecting an LED light pattern onto an object and capturing its shape with multiple cameras. The captured images are then reconstructed to create a 3D model.Structured light scanners are used for many applications in manufacturing, including inspection, GD&T analysis, and reverse engineering processes. After taking this class, users will be able to describe structured light scanners and how they function.
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Inspection 3D Laser Scanners 376
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3D Laser Scanners provides an overview of the components, functions, and applications of laser line scanners. A laser line scanner is a type of 3D optical measuring device used to record an object's geometry. Laser line scanners gather measurements by projecting a single or multiple laser lines onto an object while a camera captures its reflection. The scanned point data is used to construct a 3D model in real time.3D laser line scanners are used for many applications in manufacturing, including inspection, GD&T analysis, and reverse engineering processes. After taking this class, users will be able to describe 3D laser line scanners and how they function.
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Inspection In-Line Inspection Applications 381
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In-Line Inspection Applications offers an in-depth look at the uses of in-line inspection, or error-proofing, in a production environment. Error-proofing uses individualized setups to inspect a part while it is still in production. Gage selection for in-line inspection depends on variables such as part type, production specifics, environment, and process control needs. Possible gaging options include limit or proximity switches, counters or timers, photoelectric or laser sensors, air gages, machine vision systems, and ultrasonic systems. In-line inspection is only feasible if it can be done with repeatability and accuracy.Inspection of parts during production, instead of after it is complete, allows a company to prevent errors before they occur and reach customers. After taking the class, users should be able to describe the various methods for incorporating in-line inspection into an established production process.
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Inspection Intro to GD&T 200 (1994)
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Inspection Interpreting GD&T 310 (1994)
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Lean Lean Manufacturing Overview 101
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Lean Manufacturing Overview provides an introduction to the principles and terminology of lean strategies, including a discussion of the seven forms of waste, the definition of value-added, the difference between push and pull systems, and the importance of continuous improvement. This class also highlights other quality concepts, such as single minute exchange of dies (SMED), inventory reduction, and Five S.Lean manufacturing approaches help companies optimize their processes through organization and waste reduction. Although change can be a challenge, more efficient, streamlined processes will ultimately lead to improved customer satisfaction. This class outlines the foundational concepts and vocabulary that every practitioner needs when beginning, or continuing, a lean initiative.
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Lean Continuous Process Improvement: Managing Flow 124
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Lean Continuous Process Improvement: Identifying and Eliminating Waste 125
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Lean Developing a Lean Culture 135
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Lean Total Productive Maintenance 141
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Total Productive Maintenance introduces users to TPM concepts and principles. This class provides an overview of each key TPM pillar, including autonomous maintenance, Five S, planned maintenance, quality maintenance, kaizen, training, safety, and office TPM. TPM combines aspects from lean manufacturing and quality initiatives to create a blended maintenance approach for both production and administrative areas. Improved safety, longer machine life, and increased employee involvement are just a few benefits of a well-executed TPM strategy. After taking this course, users will be able to describe the key components of total productive maintenance and their role in continuous improvement.
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Lean 5S Overview 151
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Five S Overview provides a thorough introduction to the purpose and process of 5S quality initiatives. This class includes separate discussions on each of the five steps, along with information on challenges, advantages, and possible assessment tools.Many companies implement quality initiatives to improve operations and eliminate waste. 5S is a quality method that promotes organization, efficiency, and team work through several sequential steps. After completing this class, users will understand the value of each 5S step and be better equipped to execute and evaluate 5S.
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Lean Cell Design and Pull Systems 161
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Cell Design and Pull Systems provides an introduction to the origin, purpose, and advantages of cellular manufacturing. This class describes the basic characteristics of a work cell, along with how cells are planned, organized, and improved. Cell Design and Pull Systems also includes a discussion of related quality concepts, such as takt time, cycle time, kanban systems, and error prevention. Work cells have become an integral component of many lean facilities due to their ability to streamline operations and decrease lead time. However, cells require planning, organization, and constant team effort. In order for the system to work, everyone must know his or her role in the cell. With this class, someone new to cellular manufacturing will be able to identify the benefits of work cells, use common quality terminology, and understand how supporting strategies, such as kanban and kaizen, come together to create an effective quality system.
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Lean Intro to Six Sigma 171
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Intro to Six Sigma provides a comprehensive introduction to the goals, methods, and tools used during Six Sigma initiatives. This class discusses the different roles in a Six Sigma team, DMAIC steps, and how to identify variation. Intro to Six Sigma also covers the tools practitioners use to track and analyze data, such as Pareto charts, frequency distribution charts, and run charts. Unlike some quality initiatives, Six Sigma offers tangible, measurable methods to gage a project's success. This class gives new practitioners the foundational knowledge needed to support a Six Sigma project by introducing them to key terminology and important data analysis tools.
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Lean Troubleshooting 181
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Troubleshooting provides a comprehensive overview of various methods and tools used to troubleshoot problems. Troubleshooting often involves finding the root cause of a problem and being able to distinguish deviations from problems and early warning signs from warning signs. Many tools are used to collect and interpret troubleshooting data, including check sheets, fishbone diagrams, and Pareto charts. The 5 Why technique, brainstorming, documentation, and troubleshooting teams are common methods of gathering troubleshooting data. Troubleshooting teams gather data in order to find possible solutions. Teams must test solutions to make sure they offer long-term results.Troubleshooting is an extremely important skill for all areas of industry. The information provided in this class prepares students to solve problems and understand how to work to prevent them in many different settings. Without this knowledge, students would not be able to solve problems effectively.
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Lean Conducting Kaizen Events 191
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Conducting Kaizen Events provides a comprehensive overview of kaizen events and how they work. A kaizen event is a focused project conducted by a cross-functional team that targets a particular problem area. Kaizen events produce both quantitative and qualitative benefits, although there are some potential challenges. During a kaizen event, a team analyzes the current state of the target and plans improvements for the future state. Kaizen events require preparation, training, and follow up.Kaizen events are an important part of lean manufacturing that often lead to dramatic changes and significant results. Kaizen events optimize processes and eliminate waste, which improves quality and reduces costs. After taking this class, students will have a foundational understanding of why kaizen events are held and what happens during a kaizen event. This familiarity prepares students to participate in, and eventually lead, kaizen events.
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Lean SPC Overview 211
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SPC Overview offers a thorough introduction to the purpose and main concepts of statistical process control (SPC). This class describes different types of control charts, such as X bar, R, and P charts, and how these tools are used to determine if a process is in-control or out-of-control. Identifying and eliminating special cause variation is essential to creating quality products and reducing waste. SPC methods are an efficient, effective means to track variation and monitor processes. With SPC tools, manufacturers have the ability to find and fix issues before they lead to product problems. After taking this course, new and current personnel will understand commonly used control charts and recognize out-of-control signs, making them better equipped to contribute to quality control efforts at their facility.
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Lean Metrics for Lean 231
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Metrics for Lean provides an introduction to the information and data used to track processes in lean manufacturing facilities, including takt time, cycle time, total time of operations, overall equipment effectiveness (OEE), and first-time quality. Metrics are measurable variables that can be tracked over time in order to identify errors or gauge progress. In lean facilities, metrics are tools manufacturers use to identify non-value added activities, streamline operations, and improve operations. After taking this class, users will be able to distinguish between broad and narrow metrics and calculate key values such as takt time and OEE. Understanding this information will help users contribute to lean initiatives and everyday continuous improvement efforts.
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Lean Process Flow Charting 241
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Process Flow Charting provides an overview of the types and purposes of flow charts, including spaghetti diagrams, process maps, and value stream maps. This class describes the value of current- and future-state charts and how they contribute to quality initiatives.Process flow charts are a means to identify waste and inefficiencies in the production process. Choosing a flow chart depends on the needs and goals of the manufacturer; some charts use symbols and incorporate metrics, while others can simply be drawn by watching activities in the facility. With this class, new practitioners will learn about the development and use of flow charts and be better prepared to utilize these tools.
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Lean Strategies for Setup Reduction 251
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The class Strategies for Setup Reduction presents several common strategies for decreasing setup, the activities required to prepare a product for processing. The single minute exchange of dies (SMED) method, which strives to reduce setups to under 10 minutes, is a core approach to setup reduction. SMED focuses on transitioning internal steps to external steps, which can be performed while machines are running. Additional SMED practices include using setup teams in parallel operations and prepping tools, paperwork, and materials. Standardization and special devices like one-turn and one-touch fasteners and intermediate jigs also help reduce setup times. Setup reduction is one of the many goals of lean manufacturing. Reducing setup times allows manufacturers to perform more setups for smaller, more-varied batches so that they can better respond to customer demands. After taking this class, users should be familiar with methods and understand the importance of setup reduction.
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Lean Total Quality Management Overview 261
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Total Quality Management discusses the major principles of total quality management (TQM). TQM evolved from quality assurance methods, which emphasize quality by design. TQM is a management philosophy that focuses on customer satisfaction, since customers define quality. Efforts to improve quality are integrated throughout each stage of the industrial cycle. Leadership is responsible for creating and executing a strategic TQM plan, as well as establishing an open company culture that involves and empowers all employees. There are many methods that can be used to measure, analyze, and implement TQM.A company can be successful only if its customers are satisfied. TQM helps companies stay competitive by establishing a culture focused on customer satisfaction and continuous improvement. After taking this class, users should understand the importance of TQM and be prepared to contribute to total quality efforts in the workplace.
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Lean Management Tools: Problem Solving 270
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Lean Management Tools: Product and Process Design 275
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Lean Value Stream Mapping: The Current State 301
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Value Stream Mapping: The Current State provides an introduction to the tools and process of value stream mapping. This course explains common value stream mapping (VSM) icons, the steps to creating a VSM, and outlines how to calculate key metrics, such as cycle time, parts per hour, and capacity. Users will also be guided through the development of a current state VSM for a company making a low-variety/high-volume product.Isolating and eliminating waste are critical to achieving streamlined operations in lean manufacturing. Current and future state value stream maps are one tool companies can use to track their processes and make plans for improvement. After taking this course, users will be able to identify VSM icons, calculate critical metrics, and contribute to current state VSM development.
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Lean Six Sigma Goals and Tools 310
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Lean Value Stream Mapping: The Future State 311
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Value Stream Mapping: The Future State builds on concepts users used in Value Stream Mapping: The Current State. This class describes how to develop a future state value stream map, including how to evaluate a current state value stream map, target problem areas, and design a plan to reduce non-value added activities.A value stream map (VSM) is a process flow chart that manufacturers use to identify waste. The first step in value stream mapping is to create a current state map that represents the present flow of the facility. The next step is to identify areas of waste and develop a future state map. Future state maps represent changes the company can make to improve the facility's layout, production management, and communication systems. Reducing waste and streamlining processes is a goal in all manufacturing facilities. After completing these courses, users will be able to create VSMs and contribute to quality improvement efforts.
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Lean Maintaining a Consistent Lean Culture 330
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Lean Transforming Lean into Business Results 340
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Lean Measuring Lean Systems 350
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Materials Introduction to Physical Properties 101
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Introduction to Physical Properties provides an overview of manufacturing materials and their physical properties, including thermal, electrical, and magnetic properties. This class also introduces users to volumetric characteristics, such as mass, weight, and density. Physical properties determine how a material will react to moisture, heat, electricity, and other factors. In order to choose the best tooling or raw material for an application, manufacturers must understand the physical properties of key metals, plastics, and other materials. After taking this course, users will be able to identify and describe key physical properties and their value in a manufacturing setting.
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Materials Introduction to Mechanical Properties 111
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Introduction to Mechanical Properties provides a thorough introduction to key mechanical properties, such as tensile strength, hardness, ductility, and impact resistance. This class discusses how shear, compression, and tensile stress impact a material's properties, how force is shown on a stress-strain graph, and common methods manufacturers use to test a material's strength. To make quality products, manufacturers must anticipate how a material responds to shaping and cutting forces and understand how that material will ultimately function once it reaches the customer. Evaluating a material's mechanical and physical properties is the first step to choosing reliable tooling and processing methods. After taking Introduction to Mechanical Properties, users will know more about hardness, ductility, and strength, what materials exhibit these characteristics, and common methods a facility might use to test these qualities.
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Materials Introduction to Metals 121
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Intro to Metals provides an overview of popular ferrous and nonferrous metals and their properties. This course introduces users to the three types of metal crystal structures, how grains develop in metal, the purpose of heat treating, and how these aspects impact a material's characteristics. Steel, aluminum, titanium, and other metals have a wide range of commercial and advanced applications, including structural shapes, machine components, and medical devices. To choose the best material for a project, manufacturers must first understand how different metals respond to heat, pressure, electricity, chemical exposure, and weather. After completing Intro to Metals, users will know how various metals function in different environments, making them better equipped to select materials and tooling.
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Materials Introduction to Plastics 131
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The class Introduction to Plastics provides an overview of plastic and its properties. This course introduces users to thermoplastics and thermosets, physical and mechanical properties, polymer structure and arrangement, manufacturing methods, and common additives.Plastic has a wide range of commercial applications, including widespread usage in the medical field and the automotive industry. To choose the best plastic for a product, manufacturers must understand the physical and mechanical properties of a specific type of plastic. After completing Introduction to Plastics, users will understand how various plastics function and how they are used in different applications.
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Materials Metal Manufacturing 140
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Materials Introduction to Ceramics 141
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Introduction to Ceramics provides an overview of the general categories of ceramics and their properties. This course introduces physical and mechanical properties, atomic structure, and different types of traditional and advanced ceramics, as well as processing and manufacturing methods and end-user applications.Ceramics is a growing field in modern manufacturing and continuously provides new substitutes for traditional materials such as metals and plastics. An understanding of different types of ceramics' unique properties is necessary in order to know their appropriate applications. After completing this course, users will understand various ceramic qualities, manufacturing methods, and specific uses.
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Materials Introduction to Composites 151
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Introduction to Composites provides an overview of composite materials and their properties. This course introduces the variety of different matrix and reinforcement materials available, their specific mechanical and physical properties, as well as their use in engineering and advanced composites. This course also describes the benefits and drawbacks of using polymer-, metal-, ceramic-, and carbon-matrix composite materials and discusses appropriate applications for each.Composites are popular manufacturing materials due to their ability to exceed the properties of any individual material. An understanding of the different types of composites is necessary in order to know their appropriate applications. After completing this course, users will be able to distinguish between the different types of composites and understand their specific uses.
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Materials Polymer Composite Processes 152
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Polymer Composite Processes discusses the various common manufacturing methods for processing polymer-matrix composites (PMCs). Polymer-matrix composites are processed most frequently using open or closed molding methods. Open molding processes, which use a single-sided mold to shape a composite part, include lay-up molding, spray-up molding, and filament winding. Closed molding processes, which use a two-sided mold to shape composite material, include compression, injection, reaction injection, and resin transfer molding as well as pultrusion. The type and form of matrix materials affect which processes are appropriate to use.Polymer-matrix composites are the most widely utilized composites in manufacturing. An understanding of the various processes used to create PMC parts is essential for any composite technician. After taking this class, a user will be able to distinguish between the various polymer composite processes used in manufacturing today.
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Materials Classification of Steel 201
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Classification of Steel introduces users to steel designations systems, particularly AISI-SAE and UNS methods. This class describes classifications for plain carbon, alloy, high-strength low alloy, stainless, and tool steels, with a focus on AISI-SAE designations. There are many different types of steels, each having unique chemical contents and properties. Manufacturers distinguish between these metals by a numerical designation. In the AISI-SAE system, this number indicates the family of steel and the steel's carbon content. Some designations also describe the metal's intended use or special properties. Because composition and processing methods determine a metal's properties, understanding steel classification is critical to choosing the best material for an application. After this class, users will be able to distinguish between major types of steel classifications and describe the nomenclature used to identify various grades of steel.
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Materials Essentials of Heat Treatment of Steel 211
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Essentials of Heat Treatment provides a through introduction to steel heat treatment, including a discussion of how heat and carbon content impact a steel's microstructure. This class also describes common heat treating methods, such as annealing, quenching, normalizing, and tempering.Steel is heat treated to adjust the metal's properties. Heat treatments can increase a steel's hardness or ductility, or relieve stresses that accumulate due to other processing steps. To choose the best heat treating method for an application, manufacturers must understand how heat and carbon dictate phase changes and how different processes can be combined to produce a desired property. After completing this course, users will be familiar with heat treating theories and processes and be better equipped to use heat treatments.
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Materials Hardness Testing 221
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Hardness Testing provides a thorough overview of the most common hardness testing methods, including Rockwell, Brinell, Vickers, Knoop, rebound, and ultrasonic tests. This class presents a description of each method, along with discussions on how to choose and perform a test, how to read hardness ratings, and how to prevent common errors. Hardness tests ensure that raw, in-process, and finished materials have the correct mechanical properties. There are many different testing methods depending on the type of material, the work environment, and the desired accuracy of the reading. This course will prepare new and practicing manufacturers to choose and conduct different hardness tests by introducing them to popular methods used in the industry.
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Materials Ferrous Metals 231
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Ferrous Metals discusses the properties and applications of cast iron and steel, including an overview of plain carbon steel, stainless steel, and HSLA steels, along with an introduction to AISI-SAE designations. This course also describes gray, ductile, white, and malleable cast irons and their uses. Ferrous metals have broad commercial and industrial applications due to their strength, versatility, and relatively low costs. Fasteners, automotive components, structural shapes, tooling, and even aircraft parts can be made with ferrous metals. Understanding the range of cast iron and steels available enables manufacturers to choose reliable raw materials and effective processing methods. After completing this course, users will be better equipped to evaluate materials and anticipate how ferrous metals will function in different environments.
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Materials Nonferrous Metals 241
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Nonferrous Metals provides an overview of the properties and uses of common nonferrous metals, including aluminum, copper, magnesium, nickel, lead, and titanium. This class also discusses how refractory metals and how nonferrous metals are classified in the Unified Numbering System (UNS). Selecting the best alloy for an application begins with understanding each metal's properties and interactions. Nonferrous metals, although not as widely used as steel, are still valued as essential alloying elements or for advanced applications. After taking this class, new or practicing manufacturers will be able to identify various nonferrous metals, their characteristics, and their uses.
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Materials Thermoplastics 251
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Thermoplastics discusses the properties and applications of thermoplastics, including an overview of the amorphous and semicrystalline molecular regions found in thermoplastics. This course also describes common processing methods for thermoplastics, such as injection molding and extruding.Thermoplastics are the most prevalent type of plastic and as such it is crucial for employees to have a solid understanding of their properties and shaping processes. After taking this class, users will be able to identify different types of thermoplastics and common manufacturing methods.
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Materials Principles of Injection Molding 255
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Materials Thermosets 261
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Thermosets introduces users to the key characteristics and types of thermosets as well as common processing methods. A thermoset is a strong, rigid plastic with a cross-linked molecular structure that makes it difficult to recycle and re-use. Common thermosets include phenolics, epoxies, polyester, polyurethane, silicone, and elastomers. Many composites use thermosets as the binding matrix to create a thermally stable material. Thermosets may be molded or cast using a variety of shaping processes.After taking this class, users will understand thermosets' basic applications, unique behaviors, structures, and processing methods. This knowledge allows users to select the best thermoset for an application.
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Materials Principles of Thermoforming 265
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Materials Exotic Alloys 301
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Exotic Alloys provides an introduction to the properties and applications of superalloys and exotic metal alloys. In this class, users will learn about iron-based, nickel-based, and cobalt-based superalloys, as well as tungsten, vanadium, tantalum, and other exotic metals. Superalloys and exotic metals have unique properties for specialized applications. Complex, proprietary superalloys are commonly used in aerospace and petrochemical applications, while exotic metals are often used as alloying elements to enhance the properties of a base metal. After completing this class, users will be able to identify prominent superalloys and exotic metals and describe their uses.
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Metal Cutting Intro to EDM 100
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Metal Cutting Safety for Metal Cutting 101
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Safety for Metal Cutting provides a comprehensive overview of the safety hazards associated with metal cutting operations, such as hot flying chips, broken tools, and rotating components. In addition, the class addresses contact with cutting fluids, which can cause skin and eye irritation, and machine guarding. Manual machines often require machine guards because the operator works in close proximity with the point of operation and moving components. CNC machines often have fixed guards, which prevent the operator from reaching into the point of operation. Also, operators must handle all sharp-edged tools properly.Awareness of potential safety hazards reduces the risk of operator injury. The key to cutting safety is to follow the proper guidelines for the facility and maintain a well-organized, safe work environment. After taking the class, users should be able to demonstrate awareness of and follow proper safety protocols in a metal-cutting environment.
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Metal Cutting Cutting Processes 111
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Cutting Processes provides an introductory overview of the common metal cutting operations. To those new to manufacturing and machining, familiarity with the basic machines, tools, and principles of metal cutting is essential. The class focuses on the most common machining tools, the saw, lathe, and mill, and the common processes performed on each, such as band sawing, turning, end milling, and drilling. Cutting Processes also offers an introduction to holemaking and describes the differences between inner and outer diameter operations.A basic, foundational knowledge of metal cutting processes is essential to gain understanding of more advanced information such as cutting theory, tool and workpiece material, cutting variables, and tool geometries. After taking this class, students should be able to identify the most common cutting processes, as well as the machines used to perform them.
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Metal Cutting Overview of Machine Tools 121
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Overview of Machine Tools provides an overview of the basic machine tools used in metal cutting operations. The class describes the appearance, components, and uses of lathes, mills, drill presses, saws, and broaches. Lathes and mills are described in detail, including the various types of cutting operations performed and the different types of tools commonly used on both machines.This class provides new users with the foundational information about machine tools and their uses that is necessary for users to gain familiarity with common metal cutting machines and knowledge of metal cutting theory and processes. A basic understanding of the types of machine tools used in metal cutting operations will prepare users for becoming machine operators.
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Metal Cutting Intro to Screw Machining 160
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Metal Cutting Basic Cutting Theory 201
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Basic Cutting Theory provides an introductory overview of metal cutting theory and chip formation. The most fundamental aspect of cutting theory is the use of a cutting tool to remove material in the form of chips. Cutting tools can be divided into single-point tools, commonly used on the lathe, and multi-point tools, commonly used in milling and holemaking. The shape and type of chip created by cutting indicates whether or not cutting conditions are optimized. Adjusting tool angles and cutting variables has the largest effect on chip creation and cutting conditions.Understanding how chips are formed and what factors change or optimize chip formation is essential to performing an effective metal cutting operation. Chip formation affects surface finish, part quality, and tool life, and thus has a large effect on manufacturing economy.
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Metal Cutting Band Saw Operation 211
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Band Saw Operation gives an in-depth description of the considerations required for band sawing operations. Band sawing is a common way to perform rough cuts on raw stock, and uses a continuous, flexible metal blade looped over machine wheels. Band sawing can be performed with a variety of blade materials and styles, including different tooth spacing and geometry. The specific blade type and cutting variables used depend on the specific workpiece and cutting operation.Band sawing can be an efficient, low-cost way to rough cut stock to size. However, in order to effectively perform band sawing operations, operators must be aware of factors such as blade material, tooth set, tooth form, tooth spacing, and optimal speed and feed settings. This class provides the information necessary to identify optimal band sawing variables and conditions.
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Metal Cutting Introduction to Metal Cutting Fluids 221
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Introduction to Metal Cutting Fluids provides an overview of the use of cutting fluids in machining operations, including basic fluid safety and maintenance. Appropriate cutting fluid selection depends on the specific cutting operation and workpiece material, among other factors. Basic types of cutting fluids include various combinations of oils, water, and chemicals. Each type is classified by its contents. After explaining the basic function of cutting fluid, the class describes each category of fluid and its benefits and drawbacks.Appropriate cutting fluid use and maintenance are key factors in the success of a cutting operation. Proper cutting fluid application can prolong tool life and improve finished part quality, reducing scrap and tool cost. Awareness of cutting fluid hazards and maintenance helps increase workplace safety and reduce fluid costs. After taking this class, users will be able to identify the common types of cutting fluids and describe their optimal use.
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Metal Cutting Metal Cutting Fluid Safety 231
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Metal Cutting Fluid Safety provides an overview of the safety concerns related to working with metal cutting fluids. Some of the ingredients in various cutting fluids, as well as microorganisms that can grow in them, can be harmful. Exposure can occur through skin contact, inhalation, or ingestion. This exposure can lead to skin and respiratory disorders, including long-term illness. Safety measures, including ventilation, PPE, sanitation, training, and fluid maintenance, can reduce exposure to contaminants.Manufacturers always want to ensure that operators are safe, that they are OSHA compliant, and that they do not lose productivity due to accidents. Operations using cutting fluids have specific safety concerns that must be addressed in order to maintain a safe work environment. After taking this class, users will know how to differentiate between various cutting fluids, recognize the health risks they pose, and understand how to use, handle, and maintain them safely.
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Metal Cutting Prints for Metal Cutting Operations 241
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"Prints for Metal Cutting Operations" describes the appearance of manufacturing prints, how to interpret the information presented on the print, and the methods that an operator might use to create and measure various part features. Prints for metal cutting use a variety of symbols and shorthand to communicate all the information an operator will need to know to create a part, including dimensions of the part and important part features such as contours, tapers, and holes.An in-depth knowledge of how to read manufacturing prints is essential for any metal cutting operator. Being able to understand prints will also help to improve productivity and quality because operators will be able to quickly assess the best way to make a part and the order in which they should perform metal cutting operations. After taking this course, users will be able to recognize and interpret common print symbols and shorthand and determine how to physically create a part on a print.
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Metal Cutting Overview of Deburring Processes 251
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Overview of Deburring Processes provides an introduction to the various types of burrs and the methods of burr removal in modern manufacturing. Manual, mechanized, and automated deburring processes are commonly used for various workpieces. Each of these processes utilizes many of the same tools and methods, such as abrasive deburring and wire brushing.This class introduces users to the various deburring tools and processes that they may encounter in manufacturing settings, including how both manual tools and machines operate and what types of workpieces they are appropriate for. This foundational knowledge is necessary for any further learning or training in deburring.
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Metal Cutting Toolholders for Turning 260
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Metal Cutting Speed and Feed for the Lathe 301
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Speed and Feed for the Lathe provides a thorough explanation of cutting variables for lathe operations, including how these variables are measured, selected, and set. Many variables affect speed and feed selection, especially the type of cutting operation, tool material, and workpiece material. The class covers speed and feed selection for both manual and CNC machines.The proper selection of speed and feed is necessary to maximize tool life, productivity, and surface finish. Understanding cutting variables reduces tool wear, damage to machine components, and scrapped parts.
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Metal Cutting High-Speed Machining 310
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Metal Cutting Speed and Feed for the Mill 311
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Speed and Feed for the Mill provides a thorough explanation of cutting variables for mill operations, including how these variables are measured, selected, and set. Many variables affect speed and feed selection, primarily the type of cutting operation, tool material, and workpiece material. This class covers speed and feed selection for both manual and CNC machines.The proper selection of speed and feed is necessary to maximize tool life, productivity, and surface finish quality. Without an understanding of cutting variables, tools will wear prematurely, machine components will sustain increased wear and tear, and the number of scrap parts produced will increase.
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Metal Cutting Hard Turning 315
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Metal Cutting Cutting Tool Materials 321
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Cutting Tool Materials provides an in-depth discussion of various cutting tool materials and their properties. Effective cutting tools combine a handful of valuable properties: hardness, toughness, and wear resistance. Cutting material selection is based primarily on the workpiece material, machine tool, and cutting operation, and involves an appropriate balance of properties. Available cutting tool materials have expanded and improved over the years, ranging from the very tough and inexpensive to the very hard and expensive. Other tool modifications, such as heat treatment and tool coatings, can also improve cutting tools.Selecting the proper cutting tool material is essential for a successful machining operation. The tool material dictates the material removal rate, surface finish and tolerance, and expense to the manufacturer in the form of reduced scrap, extended tool life, production rates, and part quality.
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Metal Cutting Machining Titanium Alloys 325
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Metal Cutting Carbide Grade Selection 331
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Carbide Grade Selection describes the different carbide tool grades and explains how to select the proper grade for a cutting operation. Carbide grades are classified by two systems. The ANSI C-system lists grades of C1 through C8. The ISO classification system designates carbide grades as P, M, and K, followed by a number that further describes the qualities of the carbide. Carbide grade is often dependent on the type of metal used: tungsten, titanium, or tantalum. Grades have different levels of hardness, toughness, and wear resistance. Coating carbide tools can increase wear resistance and part quality.Selecting the correct carbide grade is essential for decreasing manufacturing costs while maximizing tool life, part quality, and production rate. After taking this class, users will be able to identify the different carbide grades and select the proper grade for a particular cutting operation.
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Metal Cutting ANSI Insert Selection 341
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ANSI Insert Selection provides information on how to identify the qualities and properties of a carbide cutting insert based on its ANSI insert number. Carbide inserts are the most commonly used tools for metal cutting and are manufactured in a variety of types that are optimized for different applications. By learning the ANSI insert nomenclature, users can identify insert shape, clearance angle, tolerance, type, size, thickness, and cutting point among other important features. These features dictate the capabilities and ideal uses of the insert.Users who understand ANSI insert nomenclature can select and order the optimal cutting insert for any given cutting process. Proper tool selection determines part quality, production rate, and tool life and is an essential component in ensuring the efficiency, cost-effectiveness, and quality of a manufacturing application.
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Metal Cutting Advanced Tool Materials 345
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Advanced Tool Materials describes advanced metal-cutting tool materials: how they are made and how they are used. Advanced tool materials include cermet, ceramic, cubic boron nitride (CBN), and diamond. Most advanced materials are harder than common tool materials, such as carbide, and they have a range of properties and applications. The primary benefits of advanced tool materials are their ability to cut hard, abrasive, and ductile materials, perform precise cuts, and cut at higher speeds.Many workpiece materials, such as superalloys and cast iron, respond best to being cut with advanced tool materials. Advanced materials can also improve the efficiency and accuracy of machining operations. An operator who understands advanced tool materials will be able to cut more kinds of materials effectively, increasing flexibility and reducing scrap and waste. After taking this course, users will know the various types of advanced tool materials as well as how and when to use them.
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Metal Cutting Lathe Tool Geometry 351
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Lathe Tool Geometry provides a description of single-point lathe tool angles, detailing the effect these angles have on a cutting operation. Tool angles have a significant impact on a cutting operation, as each angle offers a tradeoff between cutting-edge strength and improved tool service life, among other factors. Cutting tool angles must be optimized to each unique combination of workpiece material, tool material, cutting application, and desired surface finish quality.Improper tool geometry leads to premature tool wear and failure, poor surface finish, and slower speed and feed rates. These factors increase manufacturing costs, create excess waste and scrapped parts, and slow production rates. After taking this course, users will be able to better identify and implement proper tool geometry for lathe cutting processes to improve production efficiency and maximize tool service life.
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Metal Cutting Mill Tool Geometry 361
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Mill Tool Geometry provides an overview of the possible tool angles and insert features for a multi-point milling cutter, detailing the affect each angle has on a cutting operation. The various angles, such as the axial rake and radial rake, and their positioning offer tradeoffs between cutting edge strength and cutting forces, among other important factors. Mill tool geometry must be optimized to each unique combination of workpiece material, tool material, and part feature.Improper tool geometry leads to premature tool wear or failure, poor surface finish, and slower speed and feed rates. These issues can increase manufacturing costs, create waste and scrapped parts, and slow production rates. After taking this class, users will be able to identify the various angles involved in mill tool geometry and implement the proper tool geometry for mill cutting processes.
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Metal Cutting Drill Tool Geometry 371
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Drill Tool Geometry provides an overview of each tool angle for a drill, including point angle and helix angle, and details the impact that each angle has on a cutting operation. Changing the size of each cutting angle offers a tradeoff between cutting edge strength and cutting forces. Cutting tool angles must be optimized to each unique combination of workpiece material, tool material, and part feature.Proper drill geometry can prolong tool life, optimize finished part quality, and greatly improve productivity. After taking this class, users will be able to identify and implement proper tool geometry for dill cutting processes. Improper drill tool geometry leads to premature tool wear and failure, poor surface finish, and slower speed and feed rates. Poor drill geometry can also cause deflection, which creates holes at incorrect locations and with poor tolerance. These issues increase manufacturing costs, create waste and scrapped parts, and slow production rates.
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Metal Cutting Optimizing Tool Life and Process 381
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Optimizing Tool Life and Process provides a detailed overview of the various considerations necessary for prolonging cutting tool life. This class describes the various types of tool wear and provides explanations for how each type of wear occurs, as well as ways to reduce and prevent them. Cutting tool wear types include flank wear, crater wear, notch wear, built-up edge (BUE), plastic deformation, thermal cracking, chipping, chip hammering, and fracture.Tool cost is a significant component of overall manufacturing expenditures. Additionally, longer tool life leads to higher production rates, as it reduces the time spent indexing or changing out cutting tools. By learning to recognize, lessen, and possibly prevent tool wear, operators can prolong tool life, reduce tool cost, and improve productivity. After taking this class, users will be able to identify common types of tool wear and strategies to reduce or prevent them from occurring.
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Metal Cutting Impact of Workpiece Materials 391
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Impact of Workpiece Materials gives a detailed overview of the various types of workpiece materials, how they can be processed, and the challenges posed by each. Ferrous and nonferrous metals are the most common workpiece materials, and each metal has different properties and cutting tool compatibility. Non-metallic materials, such as carbides, ceramics, plastics, and composites, may require machining processes. These materials have very unique qualities, and thus have specific requirements regarding cutting tools and cutting conditions.A working knowledge of the different varieties of workpieces, their properties, and how to process them, is indispensable. In addition to understanding cutting tool properties, familiarity with the properties and demands of workpieces ensures that operators can capably run any operation. Optimizing cutting conditions leads to better products, higher output, and reduced manufacturing costs.
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Motor Controls Relays, Contactors, and Motor Starters 201
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Relays, Contactors, and Motor Starters provides an overview of the primary components involved in electric motor control. Relays are electrical switches that control a circuit. When activated by current, a relay opens and closes a circuit to turn a larger current on or off. Contactors control current by conducting it through metal contacts that make or break electrical circuits. When combined with an overload relay, a contactor becomes a motor starter.Working with relays, contactors, and motor starters requires technicians to understand how to properly care for such devices and how to operate them effectively. After taking this class, users will be able to describe the design and function of common relays, contactors, and motor starters, as well as the applications for each device.
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Motor Controls Control Devices 211
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Control Devices 211 covers the fundamental components of motor controls, devices that control the flow of current in circuits. Dangers of electric shock and other safety risks are significantly heightened when working with control devices. Control devices can be manual, mechanical, or automatic and are used in a variety of ways. Control devices include different types of buttons and switches, all of which serve differing purposes. It is necessary for those working with motor controls to understand control devices and apply their knowledge to appropriately select and operate these items according to application. After taking this course, students will be able to describe the design and function of commonly used mechanical control devices, along with applications appropriate for each device.
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Motor Controls Distribution Systems 221
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Distribution Systems 221 describes power distribution systems and their components. Distribution systems are integral parts of motor control systems because they consist of all generators, transformers, wires, and other devices used to transport power from the source to end use. Generating stations house generators that are linked together in parallel circuits to create power. Transformers step up and step down voltage. Substations house transformers and provide a safe point to cut the power.Understanding the ways in which electricity is distributed and how to work safely with distribution systems is an essential part of working within motor controls. After taking this course, users will be able to describe how power enters a facility and is distributed to electrical equipment, as well as best practices for safely working with electrical power distribution systems.
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Motor Controls Limit Switches and Proximity Sensors 231
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Limit Switches and Proximity Sensors introduces users to commonly used manufacturing sensors that detect the presence or absence of an object. Limit switches are mechanical sensors that require physical contact to be actuated. There are many variations of limit switches, including different operating mechanisms and environmental classifications. Proximity sensors, including inductive, capacitive, and Hall Effect sensors, do not require physical contact because they use an electronic or magnetic sensing field. These devices have different advantages and disadvantages and are used for various applications.Limit switches and proximity sensors are widely used for automated systems in all types of industries. They are used to control speed and motion as well as detect, count, position, and divert parts. After taking this class, users will understand the function, application, and installation considerations for commonly used limit switches and proximity sensors.
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Motor Controls Introduction to Electric Motors 301
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Introduction to Electric Motors provides a comprehensive overview of electric motors and the principles on which they operate. Electric motors use magnetic induction to turn electricity into mechanical motion. This motion is rated by mechanical power variables, such as speed, torque, and horsepower. Electric motors run on either direct or alternating current. Direct current motors include series, shunt, and compound motors. Common AC motors are squirrel cage, wound rotor, and synchronous. Different types of motors are used for different applications.All maintenance personnel must have a good understanding of electric motors because they are so commonly used. Before users can understand advanced motor control concepts, they must first develop a foundational knowledge of electric motors and how they function. This class introduces the topics that users will build on as they continue to study motor controls.
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Motor Controls Symbols and Diagrams for Motors 311
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Symbols and Diagrams for Motors introduces different diagrams used to represent motor circuits and symbols that circuit diagrams commonly contain. Pictorial diagrams are the simplest and use illustrated pictures to represent circuit components. Schematic diagrams and line diagrams use symbols to represent components. Wiring diagrams also use symbols, but they are more detailed than the other types of diagrams. Most motor control devices are represented on a schematic diagram.Being able to interpret motor diagrams is extremely important when working with motor controls because they show how circuits are constructed and how components are connected. Users will also rely on their knowledge of diagrams and symbols when learning about more advanced motor topics and applications.
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Motor Controls Logic and Line Diagrams 312
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Logic and Line Diagrams provides a comprehensive look at circuit logic and diagrams. The way a circuit functions depends on its circuit logic, which can be AND, OR, NAND, or NOR. The logic used in a circuit determines the layout of its corresponding line diagram. In general, line diagrams lay out the relationship between components on parallel lines. Line diagrams also include numbers to identify the location of components, the wires in the circuit, and the connections between components.This class will familiarize users with the rules and conventions of line diagrams, as well as the different types of circuit logic. This knowledge will allow users to read line diagrams, which is essential when working with motors and especially motor controls.
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Motor Controls DC Motor Applications 321
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DC Motor Applications provides a comprehensive overview of DC motors and their uses in industry. DC motors generally consist of an armature, a commutator, brushes, and field windings. DC motors may be series, shunt, or compound, depending on their field winding connections. Some DC motors use permanent magnets instead of field windings. In general, DC motors offer high torque and easy speed control, but they require more maintenance than AC motors.DC motors are used to provide control for many applications in industry, and most older manufacturing equipment uses DC motors. Since older equipment is more likely to need maintenance than newer equipment, personnel working with motor controls are more likely to need to service DC motors than AC motors. This class provides users with a good understanding of how DC motors work so that they can effectively operate and maintain these motors.
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Motor Controls AC Motor Applications 322
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AC Motor Applications provides a comprehensive overview of different types of AC motors and how they operate. The main components of AC motors are stators and rotors. The two basic types of AC motors are induction and synchronous motors. AC motors can operate on single-phase or three-phase power. In general, AC motors require little maintenance. Depending on its type, a motor may need to be repaired or replaced when problems occur.AC motors are the most commonly used industrial motors, and many applications that previously used DC motors are replacing them with AC motors when possible. Working with the applications that use AC motors demands an understanding of how AC motors function. After taking this class, users will have a foundational knowledge of the components, types, and uses of AC motors.
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Motor Controls Specs for Servomotors 330
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Motor Controls Solenoids 331
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Solenoids introduces different types of solenoids and their uses. Solenoids use magnetic induction to produce linear motion. Common solenoid types are direct action, plunger, bell-crank, and clapper. Solenoids are rated by their voltage and current characteristics, which helps determine the appropriate solenoid for a given application. Solenoid failure may be caused by selecting the wrong solenoid, or other common causes such as incorrect voltage or frequency.Understanding how solenoids work is necessary for working with the many applications that utilize them, including combustion engines and industrial fluid control systems. After taking this class, users will have an understanding of solenoids and should be able to identify important factors in solenoid selection and common causes of solenoid failure. Knowing how to choose the correct solenoid and avoid solenoid failure decreases the chances of solenoids burning out or needing to be replaced for other reasons.
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Motor Controls Timers and Counters 340
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Motor Controls Reversing Motor Circuits 341
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Reversing Motor Circuits provides a comprehensive overview of the various means used to reverse electric motors. Motor control circuits use various control devices to change the direction in which a motor rotates. Reversing circuits typically use reversing starters, but they may also use drum switches, limit switches, and programmable logic controllers. To reverse a DC motor, the control device changes the direction of current flow in the motor’s armature. To reverse an AC motor, the control device interchanges two of the motor’s power lines.Many applications require motors to run in reverse, either to change the direction of operation or to brake and stop the motor. After taking this class, users will understand the basic principles behind reversing circuits for motors and be familiar with the various control devices they use. This will prepare users for designing, working with, and selecting control devices for various types of motor reversing circuits.
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Motor Controls Motor Drive Systems and Maintenance 347
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Motor Drive Systems and Maintenance describes the major components found in motor drive systems and best practices for system maintenance. A motor drive system typically consists of a variable frequency drive and a three-phase AC motor used to power a driven unit. The motor connects to the driven unit through a drive train. Because there are many mechanical and electrical components, motor drive systems are prone to various faults that interrupt operation and lead to downtime. Following a proactive maintenance approach can be a very effective method of preventing and dealing with system faults.Motor drive systems are used for many industrial applications. When operating motor drive systems, understanding how they work and how they can potentially fail is essential. In addition, understanding motor drive maintenance prepares users to operate machinery effectively, reducing downtime and manufacturing costs.
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Motor Controls Electrical Maintenance for Motor Drive Systems 348
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Electrical Maintenance for Motor Drive Systems provides a comprehensive overview of the common power quality issues that occur in motor drive systems and the methods used to inspect and resolve these issues. Electrical maintenance involves inspecting input power, DC bus output, leakage current, and insulation resistance as well as checking for overloading, single phasing, electrical unbalance, transients, harmonics, and thermal abnormalities.Many industrial applications rely on motor drive systems to power output devices. Motor drive systems consist of complex electrical components and require sufficient power quality to function correctly. Power issues in any system component can cause the entire system to malfunction and fail, leading to lost production time and increased costs. This class prepares users to effectively operate and maintain motor drive systems to minimize downtime and economic losses.
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Motor Controls Mechanical Maintenance for Motor Drive Systems 349
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Mechanical Maintenance for Motor Drive Systems provides an overview of the most common mechanical faults found in motor drive systems and describes typical inspection methods for mechanical maintenance. Vibration is a major issue that can have very damaging effects. Shaft misalignment, shaft imbalance, looseness, and bearing issues are the four most common causes of vibration. Vibration inspection helps identify and correct the causes of vibration. Thermal inspection, ultrasound analysis, and oil analysis are also used during mechanical maintenance.Motor drive systems are widely used to power industrial machinery. For these systems to operate safely and efficiently, their mechanical components must be in good working order. This class provides information that helps users understand major mechanical faults and how to identify and fix them. This information helps reduce unplanned downtime and expenses.
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Motor Controls Electronic Semiconductor Devices 350
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Motor Controls Photonic Semiconductor Devices 355
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Motor Controls Photoelectric and Ultrasonic Devices 365
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Motor Controls Reduced Voltage Starting 370
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Motor Controls Solid-State Relays and Starters 375
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Motor Controls Deceleration Methods 380
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Motor Controls Acceleration Methods 385
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PLCs Introduction to PLCs 201
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Introduction to PLCs provides an overview of programmable logic controllers used in manufacturing. This class introduces the components of PLCs and their functions, provides basic information on the ladder logic programming language used in PLCs, and also gives an overview of common internal relay instructions used in PLC programs.Manufacturers use PLCs to control automated processes and machines. As Industry 4.0 and smart manufacturing are gaining widespread use, PLCs are more important than ever. Having a foundational knowledge of the basic functions of a PLC helps to increase productivity and efficiency.
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PLCs Hardware for PLCs 211
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Hardware for PLCs provides essential information on the basic functions of a PLC's hardware components and how they work together to execute a PLC program. The hardware components of a PLC are the field devices, input module, output module, central processing unit, and the power supply. The field devices are the components that perform actions in order to control a process. PLC hardware also includes peripheral devices, such as programming devices and personal computers, which allow operators to interact with the PLC and monitor programs.After taking this class, users will be familiar with PLC hardware components, basic PLC networks, and the main steps in a PLC process. Understanding PLC hardware components and how they work together to control a machine or process is essential to working with PLCs. Many industries and automated processes rely on PLCs.
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PLCs Basics of Ladder Logic 221
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Basics of Ladder Logic provides an overview of the basic principles, structure, and symbols of ladder logic programming. This class introduces the components of ladder logic programming language used in PLCs and the functions, ladder diagrams, logic gates, and common input and output instructions used in PLC programs.PLC-based automation is continually growing, and ladder logic is the primary or most common language used in PLC programming. Having foundational knowledge of basic ladder logic components and functions will aid in programmer and operator efficiency and familiarity with PLC programs.
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PLCs Numbering Systems and Codes 222
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The class Numbering Systems and Codes explains the numbering systems used with PLCs, as well as the process for converting between different numbering systems. PLCs use numbering systems to process data and perform calculations. These systems include the decimal system, binary system, octal system, and hexadecimal system. PLC operators also use codes based on numbering systems, such as binary coded decimal, when entering information into an input/output module on a PLC.After taking this course, users will be familiar with the characteristics and conversion processes for numbering systems used with a PLC. This helps operators understand the internal operations of a PLC, which may simplify troubleshooting, reduce downtime, and improve productivity.
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PLCs PLC Inputs and Outputs 231
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PLC Inputs and Outputs provides an overview of the main types of input/output modules and input/output devices, their primary functions, and their roles in a PLC process. In a PLC system, the input/output modules are connected to the input/output devices that send and receive electrical signals throughout a process. Input/output modules may operate using alternating current (AC) or direct current (DC), and may be analog or discrete, depending on the type of electrical signals they process.Having a foundational knowledge of the functions and capabilities of the input/output modules in a PLC helps users understand basic PLC operation. Being aware of the different types of input/output modules and their capabilities is essential to working with PLC systems.
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PLCs Basic Programming for PLCs 241
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Basic Programming for PLCs provides an overview of the basic principles, structure, and instructions of PLC programming. Most PLC programs use instructions written in ladder logic, which is a graphical programming language. During programming, PLC programmers enter instructions and save them to the PLC’s CPU. Most program instructions are either input or output instructions. Other common instructions include sealing and latching, one-shot, timer, counter, and sequencer instructions. Program instructions are entered with programming devices while the PLC is in program mode.PLCs are widely used throughout industry and PLC-based automation is continually growing. PLC operators and programmers must understand how PLCs work in order to function effectively and efficiently in this growing field. After taking this class, users will have a foundational knowledge of PLC programming concepts, instructions, and functions.
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PLCs PLC Counters and Timers 251
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PLC Counters and Timers provides an overview of the functions of counter and timer instructions in a PLC ladder logic program. Counter and timer instructions are internal features of a program that provide increased functionality and precision for a PLC application. Counter and timer instructions are a type of output instruction that are attached to an input instruction in the program.After taking this class, users will be familiar with the different applications for counter and timer instructions and how the instructions appear in a ladder logic diagram. This class helps users to become more familiar with PLCs and PLC programming.
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PLCs Networking for PLCs 261
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The class Networking for PLCs offers a comprehensive overview on the types and functions of the industrial networks that connect programmable logic controllers. Connecting PLCs on a network allows multiple systems to communicate and share data, resulting in better and more efficient process control. PLCs use an industrial network with components that can withstand a harsh manufacturing environment while still offering real-time communication. Manufacturers can set up PLC networks using a variety of different configurations and hardware components. The ideal setup depends on the PLC application and communication needs.After taking this class, users will be familiar with the basics of industrial PLC networks, the required network components, and common network configurations. A knowledge of industrial networks is essential for anyone working with an automated process.
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PLCs Hand-Held Programmers of PLCs 280
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PLCs PLC Diagrams and Programs 300
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PLCs Overview of PLC Registers 305
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PLCs PLC Program Control Instructions 310
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PLCs Math for PLCs 320
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PLCs Sequencer Instructions for PLCs 330
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PLCs PLC Installation Practices 340
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PLCs PID for PLCs 350
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PLCs Data Manipulation 360
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PLCs Shift Registers 370
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PLCs: Siemens Basics of Siemens PLCs 200
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PLCs: Siemens Siemens PLC Hardware 210
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PLCs: Siemens Numbers, Codes, and Data Types for Siemens PLCs 220
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This class reviews the basic types of numbers, codes, and data used by Siemens PLCs. Binary, octal, decimal, and hexadecimal numbers are covered, as well as different types of integers and scientific notation.
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PLCs: Siemens Siemens PLC Communication 230
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PLCs: Siemens Siemens PLC Inputs and Outputs 240
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PLCs: Siemens Siemens Human Machine Interfaces 250
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PLCs: Siemens Siemens SIMATIC Modular PLCs 260
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PLCs: Siemens Siemens PLC Programming Concepts 270
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PLCs: Siemens Basic Ladder Diagram Programming for Siemens PLCs 280
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This class explains how basic ladder diagram programming is used to program PLCs. It examines the basic rules that are used to construct a ladder diagram program, including Boolean logic functions. It then illustrates these rules and how they relate to hard-wired circuitry by showing the various methods used to create a start-stop control application.
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PLCs: Siemens Basic Function Block Diagram Programming for Siemens PLCs 290
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This class explains how function block diagram programming is used to program PLCs. It examines the basic rules that are used to construct an FBD program, including Boolean logic functions. It then illustrates these rules and how they relate to hard-wired circuitry by showing the various methods used to create a forward-reverse control application.
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PLCs: Siemens Ladder Diagram Timers and Counters for Siemens PLCs 300
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PLCs: Siemens Function Block Diagram Timers and Counters for Siemens PLCs 310
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PLCs: Siemens Additional Ladder Diagram Instructions for Siemens PLCs 320
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This class describes the bit logic instructions used in a ladder diagram program. Then, it more thoroughly explains compare, math, move, convert, jump, label, word logic, shift, and rotate instructions.
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PLCs: Siemens Additional Function Block Diagram Instructions for Siemens PLCs 330
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This class describes the bit logic instructions used in a function block diagram program. Then, it more thoroughly explains compare, math, move, convert, jump, label, word logic, shift, and rotate instructions.
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PLCs: Siemens Siemens SIMATIC S7-1200 PLCs 340
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PLCs: Siemens Siemens SIMATIC S7-1500 PLCs 350
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PLCs: Siemens Siemens Safety Integrated for Factory Automation 360
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This class describes Siemens Safety Integrated for Factory Automation, which incorporates safety technology into standard automation, significantly reducing engineering costs, ensuring reliable and efficient operation, and enabling greater availability.
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Safety Intro to OSHA 101
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Intro to OSHA provides an introduction to the purpose of OSHA and how its standards and guidelines affect employers and employees. Most U.S. workplaces are covered by OSHA, and its existence has greatly improved workplace safety. Some industries are not covered by OSHA, however, and some states have safety programs that take the place of OSHA. OSHA standards are enforceable by law. Compliance with OSHA standards is enforced by inspections and record keeping, which have specific steps and requirements. Employers and employees have different rights and responsibilities regarding OSHA standards. Both employers and employees benefit from basic knowledge about OSHA's purpose, standards, and practices. Violations of OSHA standards are punishable by law and render the workplace unsafe for all personnel. A basic awareness of the standards, rights, and responsibilities will help employees to bolster workplace safety as well as keep the workplace legally compliant.
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Safety Ergonomics 102
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The class Ergonomics provides an overview of the science of ergonomics and its application in the workplace. Ergonomic hazards may be present in any work environment, and are a common safety risk. Not all ergonomic risks are apparent, but they can still cause musculoskeletal disorders (MSDs). Vibration, poor posture or positioning, and repetitive motion are common ergonomic hazards, though back injuries are the most common workplace injuries. The majority of work-related back injuries are caused by unsafe lifting techniques. Even computer tasks can cause MSDs over time. Ergonomic solutions should be tailored to the individual employee performing the job or task.Ergonomic programs are an effective way for any employer to increase employee safety, decrease injury and illness, reduce sick time, boost employee morale, and reduce turnover rates. Implementing proper ergonomics in the workplace increases productivity and reduces the cost of sick leave and new employee training.
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Safety Personal Protective Equipment 111
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The class Personal Protective Equipment introduces the purpose and uses of personal protective equipment (PPE). As defined by the Occupational Safety and Health Administration (OSHA), PPE minimizes exposure to hazards and helps prevent injury. In order to select appropriate PPE, employers must first evaluate the workplace with a hazard assessment. PPE may be categorized by the area of the body it protects. PPE is available in several types, designs, and materials. Every employer is responsible for providing the appropriate PPE for workers who require it, and it is every employee's responsibility to properly wear and use PPE. OSHA does not often specify which types of PPE should be worn, but requires that employers train each employee in proper use and retrain when PPE changes or if PPE is used improperly. After taking this class, users should be able to describe OSHA regulations regarding personal protective equipment and how they impact day-to-day operations in the workplace.
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Safety Noise Reduction and Hearing Conservation 121
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In the class Noise Reduction and Hearing Conservation, students will learn about the effects of sound and noise on the body and how to protect themselves from related injuries. Occupational hearing loss is preventable through hearing conservation.The two main types of hearing loss are conductive hearing loss and sensorineural hearing loss. Hearing loss may be caused by excess noise, hereditary factors, certain drugs, or illnesses. When excessive noise is present, employees must be provided with hearing protection. Using proper hearing protection will help ensure that ears remain capable of detecting important and subtle sound changes.Students enrolled in this course will learn various ways to protect their hearing and why preventative measures should be taken to avoid hearing damage. They will be able to describe OSHA regulations regarding noise levels and hearing conservation and the impact had on daily operations in the workplace.
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Safety Respiratory Safety 131
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Respiratory Safety details the appropriate types and use of breathing equipment for various airborne hazards. There are two common types of breathing equipment: air-purifying respirators and atmosphere-supplying respirators. Employees who require breathing equipment must undergo a medical evaluation and fit-testing. OSHA requires employers to provide employees who require breathing equipment with clean respirators in good condition, and comprehensive, understandable training. Employees must be able to demonstrate their knowledge of and ability to use respirators prior to ever wearing one.Training on the use and importance of respirators is crucial to doing safe and effective work and reduces accidents, injuries, and lost work hours. After taking this class, users will be able to describe OSHA regulations and best practices for using respiratory equipment, along with environments that require this equipment.
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Safety CDC Workplace Infection Safety and Prevention 135
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CDC Workplace Infection Safety and Prevention provides a comprehensive overview of how workplaces should respond to diseases caused by viruses spread mainly through person-to-person contact like COVID-19. As workplaces struggle to find a new normal amid the global pandemic of 2020, finding effective ways of protecting against the spread of such viruses is imperative to ensure continued business operation without endangering employee health and safety. In this class, users will learn ways to create a healthy and safe work environment that incorporates common methods of preventing the spread of COVID-19 recommended by the Centers for Disease Control (CDC) and state specific guidance.
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Safety Lockout/Tagout Procedures 141
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Lockout/Tagout Procedures details the OSHA requirements and best practices for preventing accidental startup during maintenance and repair. It addresses electrical power and the many other forms of energy that a machine or device may use. All forms of energy must be successfully restrained or dissipated in order for safe maintenance. Lockout/Tagout Procedures describes using a lockout device that prevents unauthorized access of the energy-isolating mechanism. OSHA has strict requirements for lockout and tagout devices, which must be standardized, easily recognized warning signs. Users will learn OSHA's specific steps for all parts of the control of hazardous energy, from shutdown to startup, including defining authorized vs. affected employees.Following proper lockout/tagout procedures is essential to preventing employee injuries and fatalities. All employees must be familiar with lockout/tagout in order to prevent the dangers of accidental machine startup.
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Safety SDS and Hazard Communication 151
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SDS and Hazard Communication focuses on communication methods about hazardous workplace substances and how they increase employee awareness and safety. Education, labeling, data collection, testing, and other communication methods detail the dangers of specific chemicals and offer methods of protection from physical and health hazards. OSHA requires that employers establish a written hazard communication program to communicate employee responsibilities, standard implementation, chemical hazards, and safety measures. Hazard communication programs must include a chemical inventory, specific labeling, SDS for each individual chemical, and training.After taking this class, users will be able to describe OSHA regulations regarding hazardous materials and SDS and their impact on daily workplace operations. Understanding these regulations is critical in maintaining workplace safety and efficient operation.
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Safety Bloodborne Pathogens 161
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The class Bloodborne Pathogens explains the nature of common bloodborne pathogens and how to handle exposure in the workplace. A bloodborne pathogen is a microorganism present in human blood that can cause disease. Common pathogens include HIV, which causes AIDS, HBV, which causes hepatitis B, and HCV, which causes hepatitis C. Exposure to blood can occur in the workplace through work-related tasks and procedures, through accidents, or by administering first aid. To avoid exposure, workers should observe the universal precautions recommended by the CDC. Employers are required by OSHA to implement controls to minimize exposures in the workplace.Employees who understand how to protect themselves from bloodborne pathogen exposure make the workplace safer for everyone and benefit their employer. After taking this class, users should be able to describe OSHA regulations regarding bloodborne pathogens and how they impact day-to-day operations in the workplace.
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Safety Walking and Working Surfaces 171
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Walking and Working Surfaces will inform employees of the ways they can decrease the risks of injury and death regarding walking and working surfaces by following the guidelines as provided by OSHA. Hazards exist when people or objects may fall from one level to another through various openings such as floor and wall openings, floor and wall holes, platforms, or runways. All openings must be guarded by devices such as railings, covers, and toeboards. Standards regarding the construction, dimension, and usage of stairs, ladders, scaffolding, and manually propelled ladder stands are also set by OSHA. Failing to use and maintain walking and working surfaces correctly can result in serious injury. After taking this course, employees will be able to describe OSHA regulations covering safe practices with walking and working surfaces and how following those regulations will positively impact daily operations in the workplace.
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Safety Fire Safety and Prevention 181
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The class Fire Safety and Prevention examines common workplace fire safety procedures. Fires, no matter how small, should be reported immediately. Buildings are equipped with extinguishing systems that actuate an alarm and discharge an extinguishing agent to control advanced stage fires. Portable fire extinguishers are available for extinguishing incipient stage fires using the P.A.S.S. technique. Employees not authorized to fight the fire should evacuate immediately. Employers should create an emergency action plan that dictates the procedures to be carried out in the event of an emergency. In the event of a fire, employees should stay calm, follow procedures, and go directly to assembly areas. Employers must account for all employees and provide first aid until medical services arrive. After taking this class, users will be able to describe OSHA regulations regarding fire safety and how they impact day-to-day operations in the workplace.
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Safety Flammable/Combustible Liquids 191
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Flammable and Combustible Liquids describes procedures required to safely handle, store, and dispose of dangerous liquids. Flammable and combustible liquids are divided into different categories or classifications based on properties such as flash and boiling points. Anyone who must handle or transfer these liquids must take precautions such as bonding and grounding to prevent accidental ignition. OSHA requires proper hazard communication and written procedures for any process involving flammable and combustible liquids, and details various standards for methods of storage, transfer, and safe disposal.Proper handling, storing, and disposing of flammable and combustible liquids prevents costly and potentially deadly fires in the workplace. Flammable and Combustible Liquids provides users with information on liquid hazards as well as safe methods of storage, handling, transfer, use, and disposal.
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Safety Hand and Power Tool Safety 201
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The class Hand and Power Tool Safety provides guidelines for the safe use of common hand and power tools. Employees should never remove any safety guards from a tool’s point of operation unless authorized. Tools must be regularly cleaned and maintained, and all blades must be kept sharp. The worksite must be kept organized, clean, and dry. All tool applications require PPE, including eye and other protection. Before working, employees must consult the owner's manual and be familiar with how the tool functions. Employees must also use the right tool for the job and follow the work practices that are specific to each type of tool.When employees use proper safety guidelines when handling hand and power tools, their employers benefit from reduced accidents on the job and lowered costs caused by work-related injuries. Safe handling of tools also increases work quality. After taking this class, users should be able to describe the safe use and care of hand and power tools.
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Safety Safety for Lifting Devices 211
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Safety for Lifting Devices covers the different pieces of lifting equipment that may be used in the workplace and the safest ways to work with those pieces of equipment. Overhead cranes and hoists are used for lifting heavy loads. Other lifting devices include slings, portable lifting stands, gantry cranes, and derricks. Extra equipment is necessary to secure loads to lifting devices. This equipment must be inspected daily for excessive wear and damage. Understanding how to maintain and operate lifting devices will allow future operators and employers to work with lifting devices safely and effectively. After taking this class, students will be able to describe the proper steps necessary to safely lift and transport materials within the work environment.
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Safety Powered Industrial Truck Safety 221
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Powered Industrial Truck Safety provides an overview of safety topics related to forklifts and other PITs. OSHA has many standards surrounding the use of PITs in the workplace for operators, non-operators, attended vehicles, and unattended vehicles. OSHA also has detailed training requirements for PIT operators. To safely operate a PIT, operators must understand basic principles of stability, including the concepts of a fulcrum and centers of gravity. Operators must also be aware of the weight and shape of loads and what individual vehicles are capable of handling.Powered industrial trucks are a common source of workplace accidents, so a strong knowledge of how to safely operate and work with PITs is crucial for any environment where they are used. PIT accidents can lead to property and inventory damage as well as employee injury. Operators should know how to avoid OSHA violations and how to handle a load without tipping the vehicle.
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Safety Confined Spaces 231
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The class Confined Spaces explains the OSHA requirements pertaining to confined spaces. A confined space has limited means of entry or exit and is not designed for continuous occupancy. Confined space hazards are caused by the material in the confined space, the activity carried out in the space, and the external environment. OSHA requires a permit for entering any confined space with an additional hazard.Confined spaces pose a safety hazard for employees. Employers must develop a written permit-required confined space program and train and certify all permit space entrants. Training should discuss the specific types of confined spaces and hazards employees will encounter at their worksite. Entrants must wear proper PPE and use specialized equipment that does not cause additional hazards.After taking this class, the user should be able to describe OSHA regulations and best practices for performing work safely in a confined space.
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Safety Environmental Safety Hazards 241
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Environmental Safety Hazards details the risks of chemical, biological, physical, and ergonomic hazards in the work environment. Hazard exposure can cause injury and illness, causing short- and long-term effects. Many hazards can be detected using the senses, but special equipment is sometimes necessary. There are many forms of hazard communication, including SDS. Using PPE diminishes risks posed by exposure to environmental hazards. There are government agencies that help assure employees’ safety by creating standards and legislation and studying hazards. However, the employer is ultimately responsible for providing a safe and hazard-free environment.Awareness of environmental safety hazards can prevent employee injury, reducing time off and workplace accident rates. After taking this course, users will be able to identify various hazards in the workplace and their possible effects on the human body.
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Safety Arc Flash Safety 251
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Arc Flash Safety provides a comprehensive review of the ways employees can protect themselves from injuries caused by exposure to arc flash. Arc flash is an intense release of heat and light caused by a variety of workplace situations involving electricity, including equipment failure and human error. Arc flash risk assessments, boundaries, and personal protective equipment help prevent arc flash and its effects. Regular inspection and maintenance of electrical systems and machinery also help prevent arc flash.Arc flash is one of the most dangerous hazards of working with electricity. After taking this class, users will be aware of the causes and dangers associated with arc flash, as well as the precautions and personal protective equipment that can help prevent arc flash exposure. This information prepares users to work safely and effectively in environments with the potential for arc flash.
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Safety Fall Protection 261
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Fall Protection provides employers and employees with a comprehensive overview of fall safety for the workplace. Fall hazards exist when people or objects may slip or fall from elevated working surfaces. Employers must designate competent persons to assess fall risks on a worksite before work begins and as work is conducted. Additionally, employers must comply with fall protection standards established by the Occupational Safety and Health Administration (OSHA), ensure employees receive adequate training to successfully adhere to fall safety practices and procedures, and provide appropriate fall protection equipment.Falls are one of the most common and preventable causes of workplace injury. Improving fall safety measures helps reduce the risk of employee injury and death. After taking this course, personnel will understand the fall safety planning process and how to apply fall safety measures that comply with OSHA standards to ensure employee safety.
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Safety Machine Guarding 271
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Machine Guarding provides an OSHA-based comprehensive overview of general machine safeguarding practices associated with hazardous machine components, motions, and actions. In general, machine guards and safeguarding devices are considered primary safeguards against amputation and other injuries. Yet, feeding, ejection, and location are types of secondary safeguarding methods used in combination with guards and safeguarding devices. Machine guarding is particularly important during times of inspection and maintenance. Hidden hazards from potential energy put an operator at risk even when a machine is turned off. To safeguard against this and human error, lockout/tagout procedures provide a strict set of safety guidelines for everyone to follow when performing maintenance tasks. After taking this course, users will be able to identify various machine motion hazards in the workplace and develop effective safeguarding strategies to prevent injuries.
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Shop Essentials (Applied Mathematics) Math Fundamentals 101
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The class Math Fundamentals covers basic arithmetic operations, including addition, subtraction, multiplication, and division. Additionally, it introduces the concept of negative numbers and integers. The class concludes with an overview of the order of operations and grouping symbols.Basic mathematical operations are the foundations upon which all math relies. Mastery of these foundational tasks will ease a student into more complicated mathematics, such as algebra and geometry, both of which are commonly used in a variety of manufacturing environments.
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Shop Essentials (Applied Mathematics) Applied and Engineering Sciences 110
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Shop Essentials (Applied Mathematics) Math: Fractions and Decimals 111
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Math: Fractions and Decimals provides the methods used to perform basic mathematical operations using fractions, decimals, and percentages. The class covers addition, subtraction, multiplication, and division with fractions and decimals. It also discusses conversions between fractions, decimals, mixed numbers, and improper fractions.Almost any manufacturing print uses fractions and decimals in its measurements. Knowing how to handle these numbers and convert between them is an essential part of the basic skills needed to work in a manufacturing environment.
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Shop Essentials (Applied Mathematics) Units of Measurement 112
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The class Units of Measurement provides a thorough explanation of the English and Metric systems and how conversion between them occurs. The common base units of measurement are length, area, volume, mass, and temperature. The English system uses inches, feet, yards, and miles to measure length, while the Metric system uses the meter, millimeter, centimeter, and kilometer. Metric conversion requires simply knowing the equivalent number of units and moving the decimal point accordingly. When converting between Metric and English units, use a reference chart, multiply, or divide, depending on the conversion. Units of measurement are used every day in a production environment. Converting between units is often required, especially for businesses dealing internationally. After taking this class, users should be able to perform calculations involving common English units, metric units, and conversions between the two systems.
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Shop Essentials (Applied Mathematics) Manufacturing Process Applications: Part I 124
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This class introduces common metal shaping operations, including sheet and bulk metal processes, extrusion, forging, casting, and powder metallurgy.
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Shop Essentials (Applied Mathematics) Manufacturing Process Applications: Part II 125
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Shop Essentials (Applied Mathematics) Algebra Fundamentals 141
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Math: Algebra Fundamentals provides a detailed overview of the basics of algebra, including the operations needed to solve a single variable equation. Basic algebra is used constantly in manufacturing, from the production floor to the accounting department.Any time a number is unknown, algebra can be used to determine that missing value. Although algebra uses the same basic operations as other mathematics, there are several new operations used to find missing variables in problems. After taking this class, users will be able to simplify, factor, and balance basic equations, as well as calculate for missing values in equations with only one variable. The user will also be able to use algebra to create an equation based on a simple story problem.
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Shop Essentials (Applied Mathematics) Geometry: Lines and Angles 151
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The class Geometry: Lines and Angles discusses the basic building blocks of all geometry: the line and the angle. Every print used in manufacturing is composed of lines and angles which must be interpreted to manufacture the depicted part. Though part geometry can be incredibly complex, all geometric prints can be broken down into simpler lines and angles. The relationships between the various angles formed when lines intersect can be used to solve geometry problems and interpret blueprints. An understanding of lines and angles is fundamental to learning and applying geometry as well as trigonometry and calculus. After taking this class, users should have a grasp on the types of lines and angles used in geometry, the angles that are formed by intersecting lines, and tranversals. An understanding of the basics of geometry is necessary in various fields including inspection, part program applications, and other important areas of manufacturing.
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Shop Essentials (Applied Mathematics) Geometry: Triangles 161
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The class Geometry: Triangles discusses triangles and the specific mathematical operations unique to them. While the triangle is a very basic shape, it can be found as a part of more complex shapes. Triangles are often used as the basic shapes that compose three-dimensional CAD designs. Right triangles also form the basis of trigonometry. Since triangles are so commonly used, an understanding of the types of triangles and the methods for calculating missing information from them is essential to users.After taking this class, users will be able to categorize triangles by their sides and angles, calculate missing angles based on the measurements of other angles, and determine the area of a triangle.
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Shop Essentials (Applied Mathematics) Shop Geometry Overview 170
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Shop Essentials (Applied Mathematics) Geometry: Circles and Polygons 171
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Geometry: Circles and Polygons covers the specifics of geometry involving circles and polygons with any number of sides. The class includes a discussion on the internal angles of a circle as well as the method to calculate the circumference and area of a circle. Additionally, this class covers the calculation of missing angles in any polygonCircles and polygons, along with triangles, are the basic building blocks of any geometric figure. Knowledge of the calculations and uses of circles and polygons can prove useful when working with prints in any number of manufacturing capacities.
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Shop Essentials (Applied Mathematics) Trigonometry: The Pythagorean Theorem 201
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Trigonometry: The Pythagorean Theorem provides an explanation of the Pythagorean theorem and how it is used to solve various math problems involving and using right triangles. The class covers the use of powers and roots and the process that is used to solve for unknown dimensions on blueprints.The Pythagorean theorem is used to solve for the lengths of sides of right triangles. To find missing measurements in a print with a right angle, manufacturers can find or create right triangles and use the Pythagorean theorem. After taking this class, users will be able to use the Pythagorean theorem to calculate missing lengths in right triangles and solve for missing dimensions on various types of blueprints by utilizing right triangles where appropriate.
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Shop Essentials (Applied Mathematics) Shop Trig Overview 210
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Shop Essentials (Applied Mathematics) Trigonometry: Sine, Cosine, Tangent 211
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The class Trigonometry: Sine, Cosine, and Tangent discusses the three basic ratios that are the basis for trigonometry. Trigonometry is based on the specific relationships between the sides and angles of right triangles. Using trigonometry, a person can determine the missing angle and side measurements of a right triangle based on the information present in a drawing. Although solving trigonometric ratios often requires a calculator, users must know which ratios to apply to a particular problem and how to calculate them. In situations where parts are being manufactured, this knowledge is crucial to effective production of parts that require specific dimensions and angles.After taking this class, a user should be able to define the various trigonometric ratios, and use them to solve various problems, including calculating a taper angle on a print.
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Shop Essentials (Applied Mathematics) Trigonometry: Sine Bar Applications 221
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Trigonometry: Sine Bar Applications discusses sine bars and the trigonometry required to use them. Sine bars are used when an angle needs to be machined, measured, or inspected. Sine bars are used with gage blocks to set a workpiece at an angle. To find the necessary measurements for the gage blocks or the sine bar angle, trigonometric ratios are used. These ratios include sine, cosine, and tangent. Gage pins are sometimes used with sine bars and gage blocks to increase the range of measurements.After taking this class, a user should be able to make the necessary calculations for setting up a specific workpiece angle using a sine bar.
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Shop Essentials (Applied Mathematics) Interpreting Blueprints 230
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Shop Essentials (Applied Mathematics) Statistics 231
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Statistics provides a good overview of the various terms and methods commonly used for statistical analysis. In modern manufacturing, statistics are used as part of continuous improvement methods to analyze the data gathered during inspections to determine the quality of a product and examine the processes used to make it.Every person in a manufacturing environment should have an awareness of what statistical terminology and be able to use statistical concepts in the workplace. After taking this class, a user will be able to calculate the mean, median, and mode for a set of data. The user will also be able to explain the difference between natural and unnatural variation, the use histograms and bell curves, and the meaning of standard deviation.
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Shop Essentials (Applied Mathematics) Concepts of Calculus 310
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Welding What Is Oxyfuel Welding? 100
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This class describes the basic concepts of oxyfuel welding, including what equipment and gases are needed to weld. Also, it describes the various other processes that an oxyfuel torch may be used for.
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Welding Welding Safety Essentials 101
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The class Welding Safety Essentials provides a broad overview of safety topics for various welding processes. The course describes general safety practices, such as electrical, fire, cylinder, and fume safety, that welders must follow. The class also provides an overview of guideline-setting organizations, such as OSHA and ANSI.Preventing accidents is crucial to any welder or welding organization. Safety issues endanger personnel, reduce quality and productivity, and harm the performance of any organization. After taking Welding Safety Essentials, welders will be prepared to follow welding safety guidelines and will be informed about safety standards important to the welding industry, allowing for a productive workplace.
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Welding Oxyfuel Welding Safety 105
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This class covers the basic safety procedures for handling oxyfuel welding equipment, including personal protective equipment, ventilation, and fire safety.
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Welding PPE for Welding 111
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PPE for Welding introduces the purpose and uses of personal protective equipment (PPE) for welders. Welding hazards include electric shock, fume and gas exposure, arc radiation, and fire and explosion. Welders are most likely to sustain burns to the skin or eyes. OSHA and ANSI issue standards for PPE. To prevent injury, welders should wear appropriate PPE to cover all exposed skin, including safety glasses or goggles, a welding helmet, hearing protection, welding gloves, and leather high-top shoes. Welding PPE should be fire resistant, protect the eyes from harmful light, fit comfortably, and provide adequate protection. Employers must train employees in proper PPE use and complete a hazard assessment.Proper PPE not only protects workers from injury, but helps prevent productivity loss due to sick time and ensures that workplaces are OSHA compliant. After taking this class, users should be able to describe the PPE necessary to perform welding operations safely.
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Welding Welding Fumes and Gases Safety 121
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The class Welding Fumes and Gases Safety helps students to understand the dangers of fume and gas generation in welding. The fume plume, a visible cloud of smoke rising from the molten metal, consists of complex metallic oxides and particles formed from the consumable and base metal. Shielding gases used in welding may also produce potentially harmful fumes. Exposure to fumes can be managed through engineering controls, ventilation, proper PPE, and adherence to exposure limits set by OSHA or other organizations. After taking this class, the student will understand the potential dangers of welding fumes and gases, as well as the acute and chronic symptoms that may develop after overexposure. This class discusses how workplace practices and engineering controls can be used to control exposure, in addition to following Permissible Exposure Limits and using air-supplied respirators when necessary.
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Welding Electrical Safety for Welding 131
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Electrical Safety for Welding introduces users to the electrical hazards of arc welding and methods of reducing them. Arc welding requires a live electrical circuit, which presents several potential safety hazards. Electricity can cause burns, fires, and electric shock. There are two types of electric shock: primary voltage shock and secondary voltage shock. To prevent the risks associated with electricity, welders must make sure equipment is properly installed, grounded, and maintained. Welders must also use the necessary PPE and insulation to prevent injury.After taking this class, users will have a good understanding of the major safety hazards associated with electricity and precautions that minimize these risks. This knowledge allows users to work more safely and effectively with electrical equipment, which is required for all arc welding processes.
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Welding Introduction to Welding 141
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Introduction to Welding provides the foundational understanding of welding and welding processes on top of which process-specific knowledge and a more comprehensive understanding of welding in general is built. The class introduces the different welding processes as well as their general attributes and applications. In addition, it reviews joint and weld types, covers measurements which pertain to welding, discusses welding procedure specifications, and, finally, gives the user information on emerging welding practices and their effect on the practice of welding and the economy.Introduction to Welding builds foundational knowledge necessary for the educational development of any welder. Moreover, it exposes the user to conceptual ideas of welding theory and less-common welding practices such as laser welding.
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Welding Introduction to Welding Processes 151
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Introduction to Welding Processes provides a comprehensive overview of the most commonly used welding processes, including oxyfuel welding, gas metal arc welding, gas tungsten arc welding, flux-cored arc welding, and shielded metal arc welding. In addition, it continues to develop students’ understanding of measurements in welding and covers the Welding Procedure Specification from writing through testing and finally use.This class continues to develop the general understanding of welding begun in Introduction to Welding with a more comprehensive overview of each of the most common welding processes. It covers welding variables and presents an in-depth discussion of welding discontinuities that is continued in Overview of Weld Defects.
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Welding Intro to Submerged Arc Welding 160
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Welding Math Fundamentals for Welding 161
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The class Math Fundamentals for Welding covers basic arithmetic operations used in welding, such as addition, subtraction, multiplication, and division. This class discusses the concept of rounding whole numbers and decimals before or after calculating a problem. Math Fundamentals for Welding also gives an overview of fractions, which are used in welding measurements and blueprints along with decimals. Knowledge of basic math concepts is integral to a welder’s understanding of welding measurements and joint design.
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Welding Geometry Fundamentals for Welding 171
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The class Geometry Fundamentals for Welding teaches students how geometry is used in welding. A fundamental understanding of geometry and geometric concepts is a necessary skill for welding. This class discusses lines and angles, which are the basic building blocks of geometry. This class teaches users how to identify the parts of a circle and how to identify different types of triangles based on their sides and angles. In addition, this class includes lessons on how to find the area of a circle or triangle. The relationship between lines and angles can be used to read and interpret welding blueprints, as well as machine settings. After this class, users will be able to understand and work with the basic building blocks of geometry. Users will also be able to calculate the area and circumference of a circle and the area of a triangle.
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Welding Material Tests for Welding 201
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Material Tests for Welding introduces users to the types and purposes of welding material tests. Welding materials are tested to evaluate their properties, examine for discontinuities, and ensure the project meets welding code specifications. Testing can be destructive or non-destructive. Testing can also be used to classify metals according to their carbon content.This class includes lessons on non-destructive testing methods such as visual inspection, radiographic, ultrasonic, penetrant, and magnetic particle tests. Users will also become familiar with destructive testing methods such as the macro-etch test, fillet weld break test, guided bend test, and transverse tension test. After completing this course, users will be able to identify common material tests, the practical applications of destructive and non-destructive methods, and the advantages and disadvantages of each method.
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Welding Welding Ferrous Metals 211
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Welding Ferrous Metals defines ferrous metals, describes the common forms of ferrous metal, and discusses best welding practices for each. Each type of ferrous metal has different mechanical, physical, and chemical properties. Though all ferrous metals contain iron, their varying compositions require a number of different welding approaches.Ferrous metals are the most common metals that welders will encounter. Knowledge of ferrous metal types, composition, and best welding practices is crucial. After taking this class, welders should be able to identify the various ferrous metals, their properties, and the best welding practices for each type.
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Welding Welding Nonferrous Metals 212
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Welding Nonferrous Metals defines nonferrous metals, describes a range of nonferrous metals and their properties, and discusses best welding practices for each type. The nonferrous metal label encompasses a wide range of metals with varying mechanical and physical properties, all of which require different approaches when welding.Though less common than ferrous metals, nonferrous metals are used in a wide range of applications that require welding. Understanding nonferrous metals and their welding processes is essential for any welder. After completing this class, a user will be able to identify the various nonferrous metals, explain their properties, and describe the best welding approach for each type of metal.
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Welding Overview of Weld Types 221
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The class Overview of Weld Types provides an overview of different joints and types of welds as well as their applications. Common weld types such as fillet and groove welds, as well as combination, plug, slot, spot, and seam welds, are discussed. In addition, the different parts of a weld and different welding positions are reviewed. Finally, the class covers the requirements of a variety of joints. A short lesson on weld discontinuities is also included in order to introduce the concept to the user.Overview of Weld Types helps to build a solid foundation for advanced welding techniques as well as more comprehensive reviews of specific welding processes. After taking the class, users should have a good general understanding of the names and functions of different joints, weld types, welding positions, and joint requirements.
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Welding Overview of Weld Defects 222
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Overview of Weld Defects provides a comprehensive introduction to the most common varieties of weld discontinuities and distortion. It illustrates the causes of each of the twenty different weld discontinuities and defects and suggests effective solutions. In addition, it presents an overview of six different kinds of cracks and demonstrates how to prevent cracking and distortion in a finished weld.This class is especially crucial for beginning welders who do not yet have the skills or knowledge to avoid many of the mistakes that the class illustrates. Beginning welders will find this class particularly useful because it defines the reasons why defects or discontinuities may occur as well as the ways in which welders may rectify them.
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Welding Welding Symbols and Codes 231
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Welding Symbols and Codes describes how welding blueprints represent welding requirements. A weld is represented in a blueprint using a welding symbol. Welding symbols, which were created by the American Welding Society, include a reference line, arrow element, weld symbol or symbols, tail, and weld dimensions. When needed, the welding symbol will also have supplementary symbols and finish symbols.The welding symbol includes various components on the reference line to show the characteristics of the weld and provide specific instructions to the welder. After taking this class, users should be able to explain the many types of welding symbols and their characteristics, as well as the welding codes and specifications used in the welding industry.
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Welding Fabrication Process 232
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Fabrication Process outlines the procedures that a project planner should follow when creating a product from start to finish. A fabrication project can be something as simple as building a cabinet or as complex as constructing a motorcycle. After coming up with a project idea, the planner should list all of the requirements, including material, safety, and budgetary concerns. If all requirements can be met, the planner should research objects similar to the project idea and develop a design. The planner then creates a blueprint of the project, as well as a bill of materials. After deciding on the order of operations that will result in the completed project, the planner should implement the plan step by step to complete the project.There are many important considerations involved with any fabrication process. After this class, users will be able to develop a fabrication plan and complete a project.
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Welding Electrical Power for Arc Welding 241
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Electrical Power for Arc Welding explains the basic principles of electricity and the effect that electricity has on arc welding processes. Electricity travels in closed circuits. A basic circuit consists of a source, path, load, and control. Current is the flow of electricity. Voltage is the force that pushes current through a circuit. Resistance opposes current flow, but also makes it possible for electricity to perform work. Electrical work is called wattage. In welding circuits, the resistance of the arc converts electricity into light and heat, which melts the base metals.After taking this class, users will have a foundational understanding of electricity, electrical variables, and how electricity is used in arc welding. This will prepare users for welding, since every welder must understand basic electrical concepts to work with the arc and the welding equipment that produces the arc.
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Welding Introduction to GMAW 251
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Introduction to GMAW provides a comprehensive overview of the gas metal arc welding process and its equipment. GMAW is a semi-automatic or automatic process that uses a consumable electrode and a shielding gas. GMAW equipment includes a power source, wire electrode, wire feeder, shielding gas, and welding gun. GMAW typically uses a constant voltage power source and direct current electrode positive polarity (DCEP). In GMAW, there are several modes of metal transfer: short circuit, globular, and axial spray.GMAW is one of the most popular arc welding processes. Because it is semi-automatic or automatic, it is also one of the easiest to learn. After taking this class, users will be familiar with GMAW equipment and the various modes of metal transfer. This information provides the foundation necessary to learn how to perform GMAW. A good understanding of GMAW is also helpful when learning about related types of welding such as gas tungsten arc welding (GTAW).
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Welding Introduction to SMAW 252
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Introduction to SMAW covers the basic theories and practices of shielded metal arc welding (SMAW), as well as common operational procedures. SMAW is a welding process that uses shielding to protect the weld from contamination. SMAW is one of the most common arc welding processes in the world because of its simplicity, versatility, affordability, and suitability for most applications. SMAW requires a range of specialized equipment, specific electrodes, and knowledge of a number of safety precautions.After taking Intro to SMAW, welders will know how to safely handle, prepare, and operate SMAW equipment. They will know also have a basic understanding of how to perform an SMAW weld.
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Welding SAW Applications 255
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Welding Introduction to FCAW 261
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Introduction to FCAW provides a comprehensive overview of the flux-cored arc welding (FCAW) process and its equipment. FCAW is a semi-automatic or automatic process that is divided into self-shielded flux-cored arc welding (FCAW-S) and gas-shielded flux-cored arc welding (FCAW-G). Both FCAW-S and FCAW-G use a consumable, tubular electrode that is filled with flux-materials. FCAW equipment includes a constant voltage power source, wire electrode, wire feeder, welding gun, and, if appropriate, a shielding gas.Understanding the basic theory and process of FCAW is essential to using it successfully. After taking this class, users will be familiar with FCAW equipment and be able to distinguish between different methods and materials. Users will also be able to identify the performance characteristics, operating requirements, and finished weld properties of FCAW electrodes. This information provides the foundation necessary to perform FCAW successfully and safely.
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Welding Introduction to GTAW 262
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Introduction to GTAW defines gas tungsten arc welding (GTAW), describes the tools used in GTAW, and discusses the various factors that should be considered when using GTAW. GTAW, or TIG welding, is a precise welding process that uses a nonconsumable tungsten electrode and inert shielding gas. GTAW can be used on a wide variety of metals, and can be performed manually or with the use of semi-automated or totally automated systems.GTAW gives the welder increased control over the weld, which allows for the fabrication of stronger and higher quality welds. The process can be complex and requires practice to master, but the improved weld quality is vital to certain applications. By the end of this class, users will be able to define GTAW, identify the tools used in GTAW, and describe the various GTAW processes and applications.
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Welding Electrode Selection 270
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Welding Overview of Soldering 271
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Overview of Soldering defines soldering, describes the tools used in soldering, and discusses the various soldering processes. Soldering is a low-heat joining process used in applications where the heat of welding or brazing would be too great or where precise control is required. There are a number of manual and automatic soldering processes. Soldering is particularly useful in electronics and jewelry fabrication as well as in creating air and watertight seals in plumbing and other systems.After this class, users will be able to define soldering, identify the important tools involved in soldering, list soldering safety concerns, and describe the various soldering processes. It is essential for any operator who may be required to solder materials to understand the basic soldering equipment, processes, and practices.
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Welding Thermal Cutting Overview 281
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Thermal Cutting Overview provides a comprehensive introduction to the four most common industrial thermal cutting processes. Oxyfuel cutting uses a fuel gas flame that is mixed with pure oxygen. Air-carbon arc cutting uses heat generated by an electrical arc. Plasma cutting ionizes a high-powered stream of gas to create a plasma arc. Laser cutting severs metal with a highly concentrated and focused laser beam.Understanding the basic theories behind the four widely used methods of thermal cutting is essential to using them successfully. After taking this class, users will be able to distinguish between different thermal cutting methods as well as identify the equipment used for each. Users will also be able to identify the performance characteristics and safety considerations for these thermal cutting processes. This information provides the necessary information to perform thermal cutting methods successfully and safely.
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Welding Oxyfuel Cutting Applications 282
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Oxyfuel Cutting Applications provides an overview of the oxyfuel cutting process and its safety requirements, equipment components, and operating procedures. Before performing oxyfuel cutting, it is important to correctly setup the oxyfuel outfit and perform essential safety inspections. After lighting an oxyfuel torch, an operator must control the ratio of gas to produce a neutral cutting flame. During the cutting process, an operator must control specific variables, including tip height, gas flow rate, travel speed, and torch angles. Understanding these variables along with the proper cutting procedures help produce a quality oxyfuel cut.The information in this class helps prepare users to perform oxyfuel cutting, a popular thermal cutting process with a variety of applications. After taking this class, users will be familiar with many of the considerations and variables that go into oxyfuel cutting, which is essential to safely and successfully producing quality cuts.
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Welding Plasma Cutting 283
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Plasma Cutting describes plasma cutting equipment and discusses the setup and operation steps for plasma cutting, gouging, and piercing. Plasma cutting is a precise and efficient cutting method that uses an ionized jet of gas to generate a high temperature cutting arc and can be done by hand or with the use of CNC machine.Plasma cutting is an increasingly affordable and popular method of metal cutting. Plasma cutting balances the lower cost of cutting methods such as oxyfuel with the higher quality of laser cutting methods. After this class, users will be able to define plasma cutting, identify the tools used in plasma cutting, and describe the various cutting applications and processes. Understanding the basic plasma cutting functions and processes is essential for users to make precise, accurate cuts safely and efficiently.
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Welding Introduction to Automation 291
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Introduction to Automation provides a comprehensive overview of the automation technology used in welding and thermal cutting processes. Automation is the use of either CNC machinery or robotic systems to both power and perform one or more processes. Automation offers manufacturers several benefits, such as minimizing production costs and waste, reducing a part's cycle time and a work area's footprint, and improving part quality and process reliability.Understanding basic machine components, their movement, and the way in which they are controlled is essential to performing any automated welding or thermal cutting process. After taking this class, users will be familiar with automated equipment, operation requirements, and safety measures. This information provides the foundation necessary to working with automated machinery successfully and safely.
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Welding GMAW Applications 301
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GMAW Applications provides a comprehensive overview of how to perform gas metal arc welding (GMAW), important variables to consider, and how to prevent common defects. Before beginning GMAW, it is important to prepare by cleaning base metals and selecting an appropriate electrode. During GMAW, the welder controls electrode orientation and travel speed. Welders must also be aware of many variables, such as amperage, voltage, and shielding gas, and their effects. Understanding these variables helps prevent weld discontinuities and defects, including porosity, undercut, incomplete penetration, and incomplete fusion.The information in this class prepares users to perform GMAW, an extremely common welding process. After taking this class, users will be familiar with many of the considerations and variables that go into GMAW. A good understanding of these concepts helps prevent welders from producing irregular or defective welds.
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Welding Advanced GMAW Applications 302
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Advanced GMAW Applications provides an overview of various specialized GMAW processes. When performing GMAW on stainless steel or aluminum, welders must be aware of several factors. Many advanced processes use power sources that offer different types of control, such as waveform control, adaptive control, and synergic control. Advanced GMAW processes include pulse transfer, precision pulse, Surface Tension Transfer, and AC aluminum pulse. GMAW is also well-suited to automation. Robotic GMAW is one of the most popular forms of automated welding.After taking this class, users will be prepared to learn to perform more specialized and advanced GMAW processes. These processes are becoming increasingly popular because they consistently produce quality welds without the same drawbacks as conventional methods. Understanding advanced and specialized GMAW processes is important to remaining competitive in modern welding.
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Welding Arc Welding Aluminum Alloys 310
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Welding SMAW Applications 311
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SMAW Applications details the process of preparing SMAW equipment for welding and the basic steps a welder should take to perform a successful SMAW weld. Welders must be able to identify the different types of electrodes that can be used for SMAW and select the appropriate electrode for an application. A welder must then choose a method to start the arc and run a bead, and must know how to effectively break and re-start the arc when necessary. SMAW is not a perfect process, and this class covers the different flaws that a weld may contain as a result of different operator errors or other sources.To be an experienced and skilled employee, a welder must know the basic foundational techniques of the welding process. SMAW Applications teaches welders the essential components of performing shielded metal arc welding processes, as well as how to identify and avoid common discontinuities.
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Welding FCAW Applications 321
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FCAW Applications provides a comprehensive overview of how to perform FCAW processes. Before beginning FCAW, it is important to prepare the joint and select the appropriate electrode. During FCAW, the welder controls the electrode's orientation and travel speed. Welders must also be aware of many FCAW-specific variables, such as amperage, voltage, and shielding gas, as well as the effects of such variables. Understanding variables helps prevent FCAW weld discontinuities and defects, such as excessive spatter, porosity, and slag inclusion.After taking this class, users will be familiar with many of the considerations and variables that go into using FCAW processes, which is essential to producing quality welds and avoiding weld discontinuities and defects. The ability to recognize and avoid common welding issues reduces scrapped parts and increases quality.
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Welding GTAW Applications 331
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GTAW Applications provides an overview of the practical applications of the gas tungsten arc welding process. It covers all parts of the process, including personal protective equipment, power supplies, polarity, amperage, electrodes, shielding gas, cups, starting the arc, filler metal, welding techniques, possible defects, and professional and industrial applications.GTAW Applications is essential for any welder who requires an in-depth understanding of GTAW. Its focus on application extends Intro to GTAW to the practical sphere, paving the way for hands-on learning of GTAW welding.