Print

Syllabus

Welding Fabrication Processes
WE209

YEAR:

2023-2024

CREDIT HOURS:

4.00

PREREQUISITES:

Departmental Consent.

COREQUISITES:

None

COURSE NOTES:

Students required to complete WE105, WE111, WE113 and WE218 with a "C" or better to enroll in this course.

CATALOG COURSE DESCRIPTION:

Advanced training through classroom and lab/shop activities; blueprint, math, fabrication based machine operations, and welding applications to the practical application of manufacturing based process.

HutchCC INSTITUTION-WIDE OUTCOMES:

  1. Demonstrate the ability to think critically and make reasonable judgments by acquiring, analyzing, combining, and evaluating information.
  2. Demonstrate the skills necessary to access and manipulate information through various technological and traditional methods.
  3. Demonstrate effective communication through reading, writing, listening, and speaking.
  4. Demonstrate effective interpersonal and collaborative skills.
  5. Demonstrate effective quantitative-reasoning and computational skills.

AREA OR PROGRAM OUTCOMES

  1. Demonstrate the safe, effective and efficient set up of welding and cutting process to meet industry standards.
  2. Demonstrate work ethics including collaboration and communication skills.
  3. Produce and evaluate quality welds/cuts to meet or exceed industry standards.
  4. Read and accurately interpret blueprints/welding symbols.
  5. Demonstrate the accurate application of layout tools, mathematics, and measuring devices to complete assignments.
  6. Choose and apply appropriate manufacturing processes in the completion of projects.
  7. Relate theory-based welding principles to industry-based welding.

COURSE OUTCOMES AND COMPETENCIES:

  1. Evaluate presented project to formulate a plan of action to order required materials, process, assemble, finish and ship completed project to end user.
    1. Interpret blueprints to develop bill of materials needed to complete project.
    2. Develop cut list to use material in most effective way.
    3. Submit material list in correct industrial terms for material quotes.
    4. Estimate amount and cost of weld consumables needed for project.
    5. Determine approximate clock hours needed to complete a project.
    6. Determine best welding process or processes for the project.
    7. Create a weld procedure for project including machine settings and deposition rates.
    8. Create a quote that factors in all aspects of project.
    9. Communicate effectively with assigned partners.
  2. Demonstrate the safe and correct set up of required welding equipment and assigned workstation.
    1. Demonstrate electrical safety requirements needed for safe operation of various required welding processes in the weld shop or field.
    2. Demonstrate proper pre-use inspection of equipment and work area for potential hazards/safety issues, including personal protective equipment, machine components and peripheral equipment requirements.
    3. Demonstrate basic maintenance required for the process being used.
    4. Demonstrate the proper use of personal protective equipment as needed for the welding and fabrication environment and the task being performed.
  3. Demonstrate the preliminary inspection and safe use of required equipment needed to load, move and handle material or completed project.
    1. Demonstrate proper safety procedures when handling linear, sheet and plate material with forklift, overhead hoists or other lifting equipment to prevent injury to self and others around you as well as damage to equipment being used.
    2. Demonstrate the safe and controlled loading and unloading of sheet materials into shearing equipment, press brakes, roll forming equipment and CNC plasma.
    3. Demonstrate the safe loading of palletized material to prevent cascading of lost material, falling loads, or other types of uncontrolled unloading of a pallet.
    4. Fill out a full pre-shift forklift inspection record demonstrating complete understanding of components, parts and requirements of safe forklift operation.
  4. Demonstrate the safe and correct set up of required fabrication equipment.
    1. Demonstrate electrical safety requirements needed for safe operation of various required fabrication equipment in the weld shop.
    2. Demonstrate proper pre-use inspection of equipment and work area for potential hazards/safety issues, including personal protective equipment, machine components and peripheral equipment requirements.
    3. Demonstrate proper procedures used to prevent accidents when more than one operator is required to support or handle the material being worked with.
    4. Demonstrate basic maintenance required for the process being used.
    5. Demonstrate the proper use of personal protective equipment as needed for the piece of fabrication equipment and the task being performed.
  5. Demonstrate the safe and correct set up, operation and shut down of a band saw.
    1. List and use the proper PPE required for safe operation of Horizontal and Vertical band saw equipment.
    2. Identify the safety hazards associated with the use of vertical and horizontal band saw equipment.
    3. Demonstrate the setup, use and shut down of horizontal and vertical band saw equipment.
  6. Demonstrate the operation procedures needed for metal shears and iron worker type equipment used for the completion of fabrication projects as needed.
    1. Lay out raw materials to make parts for project.
    2. Perform proper nesting and squaring techniques.
    3. Perform proper settings for front and rear operated stops
    4. Cut raw materials to size within the allowed tolerance of the project blueprint or if undesignated on the blueprint /- 1/16 inch.
    5. Demonstrate the safe use of common hand tools and de-burring products to remove sharp edges after performing shearing operations.
    6. Demonstrate proper shut down and clean-up of equipment and work area.
  7. Demonstrate the operation procedures of mechanical punching operations commonly found on iron worker type equipment used for the completion of fabrication projects as needed.
    1. Explain the special hazards associated with punching processes used across various sectors of the welding and fabrication industry.
    2. Explain the need and demonstrate how to calculate proper tonnage requirements for punching various diameter holes in various thicknesses of material.
    3. Describe the various types of punching used in industry and the applications associated with them.
    4. Demonstrate safe set-up, and operation procedures of cold types punches.
  8. Demonstrate the operation procedures of industrial press brakes used for the completion of fabrication projects as needed.
    1. Explain the special hazards associated with press brake processes used across various sectors of the welding and fabrication industry including manual and CNC equipment.
    2. Explain the need and demonstrate how to calculate proper tonnage requirements for press brake operation.
    3. Describe the various types of punches and dies used in industry and the applications associated with them for forming parts.
    4. Demonstrate safe set-up, and operation procedures of a press brake.
    5. Explain the forming processes used in fabrication areas of industry.
    6. Describe and demonstrate tolerance, radius, and quality of a bend.
  9. Demonstrate the operation procedures of plate/sheet roll equipment used for the completion of fabrication projects as needed.
    1. Explain the special hazards associated with plate/sheet roll processes used across various sectors of the welding and fabrication industry.
    2. Demonstrate safe set-up, and operation procedures of a plate/sheet roll.
    3. Explain the forming processes of a plate/sheet roll used in fabrication areas of industry.
    4. Describe and demonstrate tolerance, radius, and quality of a bend.
  10. Demonstrate the programming, loading, operation, unloading and basic maintenance of CNC based cutting equipment used to produce parts needed for the completion of fabrication projects as needed.
    1. Identify and distinguish the types of automation used in the welding industry for cutting.
    2. Recommend the use of mechanical and CNC thermal cutting processes based on quantity, quality and complexity of the part needed.
    3. Identify axes on a CNC machine.
    4. Identify positive and negative movement along machine axes.
    5. Describe the role of the machine control unit.
    6. Describe different control and operation features available to the CNC machine.
    7. Describe CAD/CAM.
    8. Identify the major steps in program creation.
    9. Define the function of coordinate codes.
    10. Describe a torch path.
    11. Startup CNC cutting machine and perform basic maintenance.
    12. Nest program for machine and properly locate materials.
    13. Transfer files to a CNC cutting machine.
    14. List and use the specific proper personal protective equipment (PPE) associated with CNC cutting processes.
    15. Identify safety hazards of the equipment and gases being used in the automated process.
    16. Demonstrate the safe and correct set up, operation, and shut down of the automated cutting workstation.
    17. Explain basic trouble shooting operations for CNC cutting machines.
    18. Visually identify quality cuts.
    19. Properly unload, drain and shut down equipment.
  11. Implement the welding of components after fabrication of needed parts.
    1. Ensure that all parts are correct to drawing.
    2. Track all rework time encountered throughout entire project.
    3. Fit up and tack parts together for sub-assemblies.
    4. Demonstrate techniques used to maintain flatness, squarness, and prevent warping of final product.
    5. Remove any spatter or defects from sub-assemblies.
    6. Complete final inspection to ensure project is correct to drawing.
  12. Apply critical thinking and problem solving skills.
    1. Discuss the need for rework and the costs involved.
    2. Analyze and solve affected problem areas.
    3. Describe mass production processes.

COURSE ASSESSMENT AND EVALUATION:

1. Projects 2. Paperwork 3. Test and Quizzes 4. Homework 5. Demonstration of skills

ACCOMMODATIONS STATEMENT:

Any student who has a documented disability and wishes to access academic accommodations (per the 1973 Rehabilitation Act and Americans with Disability Act) must contact the HCC Coordinator of Disability Services, at 620-665-3554, or the Student Success Center, Parker Student Union. The student must have appropriate documentation on file before accommodations can be provided.

ACADEMIC HONESTY:

Education requires integrity and respect for HutchCC's institutional values. HutchCC students are required to maintain honesty through a "responsible acquisition, discovery, and application of knowledge" in all academic pursuits. Preserving and upholding academic honesty is the responsibility of Hut chCC students, faculty, administrators and staff.

I. Student Responsibilities

All HutchCC students are required to:

  • Submit all work in all courses without cheating, fabrication, plagiarism, dissimulation, forgery, sabotage, or academic dishonesty as defined below.
  • Provide all academic records such as transcripts and test scores that are free of forgery.
  • Refrain from participating in the academic dishonesty of any person.
  • Use only authorized notes and student aids.
  • Use technology appropriately, including refraining from submitting AI (Artificial Intelligence)-generated work without express written consent from your instructor.
  • Protect the security of passwords/login/privacy/electronic files, and maintain sole individual access for any online course information.

II. Definition of Academic Dishonesty

  • Academic dishonesty is any intentional act, or attempted act, of cheating, fabrication, plagiarism, dissimulation, forgery, or sabotage in academic work.
  • Cheating includes using unauthorized materials of any kind, whether hard copies, online, or electronic, such as unapproved study aids in any academic work, copying another student's work, using an unauthorized "cheat sheet" or device, or purchasing or acquiring an essay online or from another student.
  • Fabrica tion is the invention or falsification of any information or citation in any academic work, such as making up a source, providing an incorrect citation, or misquoting a source.
  • Plagiarism is the representation of words, ideas and other works that are not the student's own as being original to the student. A no n-inclusive list of examples includes work completed by someone else, work generated by an external entity (such as AI), omitting a citation for work used from another source, or borrowing the sequence of ideas, arrangement of material, and/or pattern of thought of work not produced by the student, even though it may be expressed in the student's own words.
  • Dissimulation is the obscuring of a student's own actions with the intention of deceiving others in any academic work, such as fabricating excuses for absences or missed assignments, or feigning attendance.
  • Forgery of academic documents is the unauthorized altering, falsification, misrepresentation, or construction of any academic document, such as changing transcripts, changing grades on papers or on exams which have been returned, forging signatures, manipulating a digital file of academic work, or plagiarizing a translation.
  • Sabotage is any obstruction or attempted obstruction of the academic work of another student, such as impersonating another student, stealing or ruining another student's academic work.
  • Aiding and abetting academic dishonesty is considered as knowingly facilitating any act defined above.
  • Academic honesty violations can also include the omission or falsification of any information on an application for any HutchCC academic program.

III. Sanctions for Academic Dishonesty

Students who violate the Academic Honesty Policy may be subject to academic or administrative consequences.

Instructor Sanctions for Violation:

Students suspected of violating the Academic Honesty Policy may be charged in writing by their instructor and any of the following may apply:

  • Assign Avoiding Plagiarism Bridge Module
  • Receiving written warning that could lead to more severe sanction if a second offense occurs
  • Revising the assignment/work in question for partial credit
  • Voiding work in question without opportunity for make-up
  • Reducing the grade for work in question
  • Lowering the final course grade
  • Failing the work in question

Institutional Sanctions for Violation:

Students charged with academic dishonesty, particularly in instances of repeated violations, may further be subjected to an investigation and any of the following may apply:

  • Instructor recommendation to the Vice President of Academic Affairs (VPAA) to dismiss the student from the course in which the dishonesty occurs
  • Instructor recommendation to the VPAA to dismiss student from the course in which the dishonesty occurs with a grade of 'F." Student will not be allowed to take a 'W' for the course
  • Instructor recommendation to the VPAA that the student be suspended and/or dismissed from the program
  • Student barred from course/program for a set period of time or permanently
  • May be recommended by the instructor (after documented repeated offenses) to the VP AA that the student be placed on probation, suspended and/or dismissed from the institution.

IV. Procedure

  • Instructor will communicate in writing via the student's HutchCC email account and/or LearningZone email account to the student suspected of violating the Academic Honesty Policy.  That communication may include sanction(s). Department Chair will notify the student's academic advisor upon receipt of the Academic Honesty Violation Form.
  • For each violation, the instructor will submit a completed Academic Honesty Violation Form to the Department Chair. Department Chair will notify the student's academic advisor upon receipt of the Academic Honesty Violation form.
  • Should the instructor choose to pursue institutional sanctions, the instruct or shall notify the student in writing via the student's HutchCC email account.  Instructor shall also submit a completed Academic Honesty Violation Form and all prior completed forms regarding said student to the Department Chair and the office of the VPAA with recommendation to proceed with specific Institutional Sanctions. Department Chair will notify the student's academic advisor upon receipt of the Academic Honesty Violation Form.
  • The decision of the VPAA on Institutional Sanction is final. The VPAA will notify the student's academic advisor of any institutional sanctions.

V. Due Process Rights

Students charged with violations of academic honesty have the right of appeal and are assured of due process through the Academic Honesty Appeal process.

Academic Honesty Appeal Process

I. Due Process Rights: Students charged with violations of academic honesty have the right of appeal and are assured of due process through the Academic Honesty Appeal process.

  • If an instructor has recommended course or program dismissal, the student may continue in coursework (provi ding there are no threatening or security behavioral issues) until appeal processes are concluded. However, if an issue has been documented at a partnership location (e.g., clinical sites, secondary institutions, correctional or military facilities), then the student is no longer eligible to continue participation in internships, apprenticeships, and/or clinical-based practice. For clinical sites, this sanction is immediate.

II. Process

If the student disagrees with the charge of a violation of academic honesty, the student has the right to due process as described in the Academic Honesty Appeal process below:

  • If the matter is not resolved upon communicating with the instructor about the violation, the student shall, within five business days of the issuance of the written notice of violation, submit a completed Academic Honesty Appeal Form and supporting documentation to the appropriate department chairperson to initiate an Academic Honesty Appeal.
  • Within two business days of receiving the student's completed Academic Honesty Appeal Form, the Department Chair and VPAA will review and the VPAA will render a decision.
  • Within two business days, a response will be sent to the student's HutchCC email address. The VPAA's decision is final.

INCOMPLETE GRADE:

Instructors may give a student a grade of Incomplete (I) under the following conditions:

  1. The student must initiate the request prior to the time final course grades are submitted to Records.
  2. The request must be made because of an emergency, illness or otherwise unavoidable life-event.
  3. The instructor must agree to the request before a grade of Incomplete can be submitted.
  4. A written contract between the instructor and student, signed by both, will document the work required and date needed to complete course work.
  5. If a student does not complete the course requirements within the time frame established by the instructor, a grade of "F" will be recorded on the student's transcript at the end of the next semester.

HLC ACCREDITATION:

Hutchinson Community College is accredited by the Higher Learning Commission (HLC). The Higher Learning Commission is one of six regional institutional accreditors recognized by the US Department of Education and the Council on Higher Education Accreditation (CHEA).

Last Revised: 03/30/2023