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Speaking of Precision

Speaking of Precision is a knowledge preservation and thought leadership blog covering the precision machining industry, its materials and services. With over 36 years of hands on experience in steelmaking, manufacturing, quality, and management, Miles Free (Milo) Director of Industry Research and Technology at PMPA helps answer "How?" "With what?" and occasionally "Really?"

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Six Reasons Why Physics Is Critical To Contract Machining

Posted April 29, 2011 8:30 AM by Milo

Great question came in the other day.

"Since the computers control the machines, why do we need to have physics in our graduation curriculum?"

I won't tell you the State Board of Education that was looking at removing Physics from the high school curriculum.

Apparently, they don't see a need for a person entering the Precision Machining workplace to know any physics.

Who needs physics to push a button?

If they don't understand the forces around them, how can they keep from getting hurt?

Here's what I shared with them.

Since everything is computer controlled - that's the new MAGIC, right? - why would any high school graduate going into the workplace these days need to know any physics? I'm guessing that, "so they can understand how the electricity that powers his machine, the computer, and the lights," isn't a good enough answer.

1) Power and Work: All machines are horsepower-rated. This determines what jobs they can perform. Materials are machined based on horsepower per cubic inch of removal per minute. By the State Board's reasoning, "Since the clock takes care of the minutes, are we okay to just not know any of this?"

2) Mechanics: This is our craft! We need leverage, thread pitch, gear ratios, belts and pulleys. We calculate the surface feet per minute of rotating tools or workpieces, given the RPM and diameter. Even the computer needs this info. Cams, clutches, springs, motors, friction and frictional losses - these are physics. Bearings, force, stress, strain - these are applicable to understanding the machining task regardless of machine control type. Compressed air-expansion, horsepower required, volume, fluid flow…

3) Heat: Heat is the enemy in machining operations. Why not learn a little bit about this? Savvy shops today are using infrared thermography to detect bearing wear in equipment. Some kinds of tool failure are caused by heat. Understanding insulation, conduction, thermal expansion and contraction are key if the parts will be in spec after they have cooled down post-machining.

4) Sound: Decibel measurement is important as applied to occupational exposure. Harmonics come into play on tools and workpieces as oscillation - chatter. Water hammer in plumbed systems and fluid power applications.

5) Light and optics: Non-contact gaging using lasers, optical projectors for quality control; optical flats for high precision measurements rely on counting interference bands. We use portable spectrometers for product sorting. Someone in the shop will need to have an understanding of spectrums, wavelengths, and emissions if they are to be more than an idiot-operated go/no go gage.

6) Magnetism: Magnetism can cause surface finish problems if chips cling to work. There are several types of magnetic tests performed in our shops and those of our suppliers. They use eddy currents, permeability, gauss, oersteds, saturation, coercivity. We employ magnetism for proximity detection of parts, magnetic workholding, and for testing. It goes with out saying that it is magnetism in the electric motors that drives our machines.

What do you think about this topic? Do the people showing up looking for work have what it takes to understand your process? Or are they merely able to do what they are told?

Editor's Note: CR4 would like to thank Milo for sharing this blog entry, which originally appeared here.

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#1

Re: Six Reasons Why Physics Is Critical To Contract Machining

04/29/2011 9:19 AM

Looks like you gave a pretty good response to the question. (I can't immediately think of anything to add.)

Congratulations / thanks!

I hope that changed a few minds.

BTW: I agree that physics should be taught (to lots of people). I think there is room to teach more of physics by alternate methods, today. For example, use more well produced videos of good lecturers, for example, rather than pay a live teacher to do all the lecturing.

(What I mean by well produced is not what Hollywood would consider well produced--I actually mean very spartan by Hollywood standards.)

Similarly, more well produced (again) videos of experiments. Or computer based "simulations" of experiments.

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#2

Re: Six Reasons Why Physics Is Critical To Contract Machining

04/29/2011 12:47 PM

Another good reason to retain physics in high school is: To provide a complete well educated individual. Maybe we should eliminate handwriting because we use computer keyboards and mathematics because we have calculators.

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#3
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Re: Six Reasons Why Physics Is Critical To Contract Machining

04/29/2011 2:43 PM

I propose we also slash speech, communications, spelling, grammar, and basic writing skills...

Al u ned is d ablity 2 decode 2days new txting an twitr msgs 2 comuncte. no 1 seem to talk :) to :) nemore. Seems new gens hav made a new languidge.

Wow... that was incredibly hard to do.

Communication is done through texting/facebook/twitter now... Why bother teaching speech, communications, proper writing/reading?

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#4
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Re: Six Reasons Why Physics Is Critical To Contract Machining

04/29/2011 3:24 PM

I am pretty sure they are eliminating it. At least the cursive writting part of penmanship.

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#33
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Re: Six Reasons Why Physics Is Critical To Contract Machining

05/04/2011 12:42 PM

Where I live, the schools are still teaching the "three R's". My grandkids bring homework home every day and I still get to help them.

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#5
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Re: Six Reasons Why Physics Is Critical To Contract Machining

04/29/2011 3:26 PM

oops. sorry for the duplicate post

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#6

Re: Six Reasons Why Physics Is Critical To Contract Machining

04/29/2011 11:29 PM

Back in the early 1990's, I attended a PTA meeting where a first-grade teacher insisted it was no longer necessary to teach spelling because we all have spell checkers on our computers...I think they had already stopped teaching basic arithmetic since all first graders had their own calculators...

How many more years before they declare schooling totally redundant?

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#11
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Re: Six Reasons Why Physics Is Critical To Contract Machining

04/30/2011 10:25 PM

My second niece..when she was in primary [elementary] school did not get her spelling corrected as it was considered to have a negative impact on their 'growth' - or put another way..don't correct the kid as they'll get a life long complex ! That was in the late 70's / early 80's !

Now what do we have ? Something I call 'functional illiterates' who don't know how to tell time with an analogue clock, can't spell and can't do simple arithmetic [math] or only with a calculator !

When I was in college in the 'States [similar time frame to my niece's schooling] ..to do our calculations we had to get a rough figure first, note it down, then use the calculator for a more precise answer.

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#13
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Re: Six Reasons Why Physics Is Critical To Contract Machining

04/30/2011 10:56 PM

Phil,

Judging by some of the "work" I've seen in QLD Primary schools, the teacher may not have had the ability to actually correct the spelling.

In line with your next post, I remember a teacher sending a sheet home with one of my girls showing what each port or area was famous for, and Port Hedland being listed as a major Wool Exporter (among other errors). When I carpetted the Principal about the errors his response was, "Maybe you should teach the kids!"

For non Aussies Hedland is a massive Iron Ore exporter followed by Salt and Manganese. There are absolutely no wool stores in the place.

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#14
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Re: Six Reasons Why Physics Is Critical To Contract Machining

04/30/2011 11:02 PM

EMJAY it could have been worse..the teacher could have suggested that Hedland exported WOOD chips!

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#15
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Re: Six Reasons Why Physics Is Critical To Contract Machining

05/01/2011 8:50 AM

You are right there Phil.

I believe that the word "fail" is now no longer used in schools today........something like "intellectually challenged"........that probably okay because they do not understand the meaning of the word anyhow.

You dare not make a child repeat a class because it would have deep psychological effects on the child. As you said it does not matter whether or not the child has a basic understanding of the 3 "R's", pass them at all costs.

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#34
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Re: Six Reasons Why Physics Is Critical To Contract Machining

05/04/2011 12:46 PM

Are you saying this is the case in Australia? I know it's true in the U.S.

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#35
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Re: Six Reasons Why Physics Is Critical To Contract Machining

05/04/2011 8:20 PM

Unfortunately here in Oz our Government education system legislators seems to look around the world for all the worst ideas and implement them and then ignore the evidence when those approaches are either disproven or proven to be actually harmful.........

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#36
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Re: Six Reasons Why Physics Is Critical To Contract Machining

05/05/2011 9:48 AM

That's correct ronseto, I remember reading an article on it not long ago.

Whether this applies to all schools in Australia, I don't really know, my youngest is 40 years old, so it's been a while since I had kids at school.

Personally, I am involved in adult education in the the fishing and maritime industry and I will certainly fail a student if I do not consider them competent in their job. I work in a private RTO (Registered Training Organisation), therefore we have no problem in failing students, not being under government controls.

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#37
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Re: Six Reasons Why Physics Is Critical To Contract Machining

05/05/2011 9:57 AM

Hey, you actually fail students. This means that your education has some real value because only some people can obtain a passing grade. Where have I heard this idea before.

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#38
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Re: Six Reasons Why Physics Is Critical To Contract Machining

05/06/2011 6:03 AM

Yes it's actually quite good to be able to do that, especially when you know that some these students will actually be in charge of the engineering department on a vessel.

If they don't know their job, relevant to their particular certificate competency, they are going to be a danger to themselves, the vessel and the rest of the crew aboard that vessel...........and I don't really want to attend a Marine Court of Inquiry re loss of life or loss of a vessel...........and the question is asked, "Was this person a competent engineer?" and I know that I could answer, yes.

............but, in answer to your question, YES I actually fail some students heaven forbid!!!!

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#39
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Re: Six Reasons Why Physics Is Critical To Contract Machining

05/06/2011 12:25 PM

Unfortunately, we are all dependent on others doing their jobs competently- not just those that chose to go to sea. I think we would all be better off if more people were required to demonstrate competency. Bridges fall, buildings collapse- but these are not the only problems caused by incompetence. Think of the maintenance cost for your vehicle resulting from all the pot holes in the roads, for example.

Recording the fact that someone has failed to meet minimum standards is less costly in the long run than paying for the errors they cause...Besides, if you fail a lot more students, the "stigma" is lessened, and you improve the quality of the students that do get through...

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#7

Re: Six Reasons Why Physics Is Critical To Contract Machining

04/30/2011 12:30 AM

'Let there be darkness', the board said: and there was darkness.

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#8
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Re: Six Reasons Why Physics Is Critical To Contract Machining

04/30/2011 12:43 AM

And saith the Board, "It is good"(!)

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#9
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Re: Six Reasons Why Physics Is Critical To Contract Machining

04/30/2011 1:41 AM

Amen.

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#10

Re: Six Reasons Why Physics Is Critical To Contract Machining

04/30/2011 2:53 AM

Great Post! Thanks Milo!

I would add some chemical and biological knowledge: paint, glue, lubricants, poisons (also if metallic), and also material knowledge beyond the metallic (never complete) materials: ceramics and insulators are essential machine components.

I fear we are like Kassandra in the war of ancient Greece against Troy: she knew about what would happen, told everybody about, but nobody liked to hear - until too late.

I have a feeling that we are near a second medieval time where not science and technology will any more govern the western world but occultism and fundamentalism. Many young people believe in fairy-tales about the mighties of crystals and more nonsense that we have seen before. We have to stop this else we will be back to pre-industrial times within 100 years.

RHABE

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#12
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Re: Six Reasons Why Physics Is Critical To Contract Machining

04/30/2011 10:36 PM

By government edict..Australia may be reverting to 'pre-industrial times'. Almost nothing is manufactured here anymore, we have become a giant quarry for others. What happens when the coal, iron ore, bauxite, gold, uranium etc run out..then what? Do we come an agrarian society like the first white settlers? Try telling that to the city slickers in the most urbanised country in the world!! However those pushing the carbon pollution and overpopulation points of view may well be delighted !

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#16

Re: Six Reasons Why Physics Is Critical To Contract Machining

05/01/2011 12:19 PM

Very nicely done, Milo.

All too often a board member's desire to remove anything from a curriculum comes from their misunderstanding of the topic. Often this is accompanied with some student they know and care for that is failing the topic. This thread is a perfect example. Had the board member (or who ever posed the question) understood Milo's introduction to how critical (Newtonian) Physics is to a machinist, they would never have asked the question. Possibly the Physics in question was the new Physics of Quantum Mechanics and its many very baffling uncertainties.

This gets back to my proposal I made long ago on another thread. A fundamental problem in todays education is the concept that failure can be obliterated. To put this into a Zen like perspective, without failure there cannot be success. Allow me to put my proposal into this particular scenario. All High School students must take a Physics class but all of them do not have to pass. Those who wish to be machinists or mechanical engineers do have to pass Physics but those students pursuing an acting career do not. Similarly, all students should take some artistic classes but a machinist or mechanical engineer does not have to have a passing grade here. We do not all have the same aptitudes that are part of our nature.

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#17
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Re: Six Reasons Why Physics Is Critical To Contract Machining

05/01/2011 5:58 PM

Wait a minute, redfred! Machinists and Mechanical Engineers are ARTISTS of the HIGHEST CALIBER!

If a candidate for these professions can not pass basic artistic classes, maybe they should consider another field, like politics or something...

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#19
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Re: Six Reasons Why Physics Is Critical To Contract Machining

05/01/2011 11:45 PM

There clearly is artistic beauty in every engineering field. I've fabricated a few electronic circuits in my time that I believe has artistic elegance. But I would not call any drawing or schematic I've made art. I would not even call it industrial art. But I don't believe that a machinist or mechanical engineer must be capable of sketching the human figure in pencil on paper, to understand the structure of a Bach fugue, or a Shakespearean sonnet to be able to perform their craft or science. I do expect a machinist or mechanical engineer to know the fundamentals of Newtonian Physics. I do expect a professional sketch artist to be able to draw a face as a recognizable individual. I do expect a professional musician performing baroque era music to understand the structure of a fugue. I do expect a thespian of the bard to understand a sonnet from a soliloquy.

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#21
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Re: Six Reasons Why Physics Is Critical To Contract Machining

05/02/2011 12:40 AM

An engineer who has the ability to whip out an understandable hand sketch on the spur of the moment is worth considerably more than an engineer who can's- and the machinist who can turn the part described by the hand sketch into a quick prototype while singing one of the Bard's sonnets to a variation on a theme by Bach is a pleasure to work with...

Actually, mathematicians make good musicians, according to some studies I have read. If one's education is too narrow, one is handicapped in any profession.

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#26
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Re: Six Reasons Why Physics Is Critical To Contract Machining

05/02/2011 2:47 PM

Pretty high Standards there! Good for you. Good for us.

Milo

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#43
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Re: Six Reasons Why Physics Is Critical To Contract Machining

05/07/2011 5:40 AM

......I do expect a thespian....

........is that something like a lesbian!!!...........sorry, couldn't resist that one.

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#23
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Re: Six Reasons Why Physics Is Critical To Contract Machining

05/02/2011 12:34 PM

No No no ........ allow the holy book from the World Trade Organization to sort this out.

An engineer's drawing, plan, blueprint etc. is classified under 4906.00 in the chapter entitled printed matter.

Any other painting or drawing done by hand is classifed under 9701.10 in the chapter entilted works of art.

Now to take ubsurdity to a new height Canada further breaks down 9701.10 into "originals done by artists" (duty free) or "other". (5.5% duty)

This allows the same government that spent 2 million dollars on a painting of three stripes, to decide just who is an artist?

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#18

Re: Six Reasons Why Physics Is Critical To Contract Machining

05/01/2011 7:36 PM

Without Physics no one will be able to design new complex products for these machines and computers to manufacture!

Without Physics no one will be able to design the next generation of machines and computers!

Without Physics even the maintenance of the current generation of machines and computers becomes questionable.......!

Without Physics we lose the joy of understanding how and why things work!

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#20

Re: Six Reasons Why Physics Is Critical To Contract Machining

05/02/2011 12:10 AM

Who works with the hands is a laborer;
Who works with the hands and the head is a craftsperson;
Who works with the hands and the head and the heart is an artist.
--source unknown

We have seen enough artistry here on CR4 to agree with CWarner, and also to recognize with redfred that the art of engineering may be different from (though in the same spirit as) other arts.

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#22

Re: Six Reasons Why Physics Is Critical To Contract Machining

05/02/2011 12:28 PM

What a interesting "coincidence" that this topic in my email of highlighted threads was preceded by "Is Simpler Better for Failsafe?" They are quite allied, no? And neither scenario supporting "older" ways of doing things is so far fetched. Power does go out. And despite one's best efforts to avoid it () you'll be caught without your PC, calculator, or Me-phone and have to do some manual math.

We are all spoiled to electronic gadgetry. During my Jr. and Sr. year of High School, there was still a "Slide Rule Club." Does anybody here remember that?? There were "Meets" between schools, with District and State awards. I remember talking to the Chemistry teacher who taught the SRC many years later, and was shocked and saddened that it had morphed into the Calculator Club!!??

I guess every generation thinks the succeeding one is a little softer and less capable to handle life at a basic level. Growing up in the '50s was almost a "bridge" generation, in that, that is when electronic marvels began to appear, like TV, touch-tone phones, etc. Not to mention the explosion of electric appliances. Do we really need all the specific appliances? I can cook rice in a pot, I don't need a rice cooker. I look at all the infomercials (what info., huh?) and think I just haven't watched enough of these things... I haven't seen the electric or automated nose-picker... you know, the one that works while your asleep.

As to the relevance of Physics, even a stay-at-home Mom will find the benefit of seeing life through a scientifically flavored lens. Imagine all the wonders of raising a child that would be missed without it. What angle must little Johnny have run into that tree to cause the bruises he now has? (Oh, wait, CSI can provide that information.) What must the constituency of that poop be to get that color and pattern in the diaper?

Lame attempt at humor, but not really being totally facetious. I never had children, but I do remember asking the proverbial "Why" a lot of my parents. They usually didn't have a good answer to technical "whys" because of their education level. And I remember asking why a lot in school. Maybe I was dense, but if I wasn't following what the teacher was trying to explain, I didn't sit there in silence. I wasn't afraid of appearing dumb in front of others. I hated the thought more that I was going to be the only one in the class who didn't "get it."

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#25
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Re: Six Reasons Why Physics Is Critical To Contract Machining

05/02/2011 2:45 PM

I don't think this should be considered off-topic, and voted appropriately. But, I have to tell you that, since the only slide rule I have left is the slide rule simulator on my computer, when the lights go out, I'm out of luck...

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#28
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Re: Six Reasons Why Physics Is Critical To Contract Machining

05/02/2011 4:29 PM

It's never too late.

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#29
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Re: Six Reasons Why Physics Is Critical To Contract Machining

05/02/2011 4:51 PM

Whaddayamean, never too late??? Every one listed that I might be interested in has a "Sorry, Sold!" tag on it!

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#31
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Re: Six Reasons Why Physics Is Critical To Contract Machining

05/02/2011 7:50 PM

Sorry. I guess I jumped the gun. I just searched and it looked like a good site... looks can be deceiving, eh? And I should know better than to jump the gun. I've been burned too many times that way before. You'd think I'd know better.

Maybe I can make up for it. Check out E-bay. Of course, you'll have to know a bit about makes and models to sort it out. But the prices on some of them look pretty reasonable. And there appear to be more than you would think available. Hey, some of the people I work with haven't even heard of slide rules. Unless some collector drives the price up you might get a decent deal.

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#30
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Re: Six Reasons Why Physics Is Critical To Contract Machining

05/02/2011 7:34 PM

But did you get answers to your questions when asking "Why?"

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#40
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Re: Six Reasons Why Physics Is Critical To Contract Machining

05/07/2011 12:31 AM

I remember the time that...

I needed to do some moderate calculations {say ln(x) level}. I went for my scientific calculator and it was GONE!! So I went to my wifes desk and she had a couple of 4 function calculators, which were of no value to me. I spent about two hours tearing the house apart with no luck. Then I got PISSED! I went to a box and pulled out my Pickett slide rule from my college days, and with paper and pencil, and my trusty slip stick, cranked out my equations. None of the rest of the family know how to use one, so I knew it would be there.

Bill

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#41
In reply to #40

Re: Six Reasons Why Physics Is Critical To Contract Machining

05/07/2011 2:11 AM

Nice story...
But doncha know the calculator in accessories on the PC does have scientific functions if you click 'view' there are options for 'programer' 'scientific' and 'statistics'
Del

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#42
In reply to #40

Re: Six Reasons Why Physics Is Critical To Contract Machining

05/07/2011 3:05 AM

..........and at least on the old "guessing stick" the batteries do not run out!!

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#24

Re: Six Reasons Why Physics Is Critical To Contract Machining

05/02/2011 12:51 PM

Something to bear in mind, most school teachers have never taken a physics course in their life,and from an economic standpoint it is harder to retain a qualified hard sciences educated college graduate than a soft sciences educated one to teach "sciences". In colleges there is a huge gap between the more rigorous sciences, mathematics and engineer, and other disciplines. Many colleges have been dumbing down the curriculum for decades for degrees in bio-"sciences", social "sciences", education, etc.. However, they are constantly pushing for the maximum allowable course loads for hard sciences and engineering, because they feel the education is necessary for those fields. They actually have different degrees for science and engineering majors (BS) and teaching majors (BA) that differ by a matter of 30 to 50 quarter units (12 units is a full load per quarter). Physics and Chemistry are space intensive courses that require expensive class-specific laboratory space and more time involved than say most any other course in a school. The qualified teachers are hard to find, and the teachers they use tend to hate teaching such courses due to the work load. They do not help get them lowest common elements in the school to pass the minimum required national testing as the student who take such courses are already well beyond that national standard just to meet the pre-requisites for the course. from a short term local fiscal benefits standing, it is better to defer such education off onto the universities to handle as remedial coursework (I understand the UC system already has something in excess of 50% of freshmen entrants having to take remedial courses in science and math just to qualify for the entry level college coursework, so what are a few more in the overall, scheme of things).

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#27

Re: Six Reasons Why Physics Is Critical To Contract Machining

05/02/2011 2:50 PM

Thanks for the Great discussion Guys!

Milo

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#32

A little bit off topic

05/03/2011 11:00 AM

You guys have said most of it already, and I'm sure you can guess my views.

I had a nice experience at the weekend, I was demonstraing my bowmaking at a local spring fair along with some 'have a go archery'.
There were some young kids hanging around all day asking questions so fast I could barely get time to answer, they were a bit boisterous but basically well behaved. Eventually the oldest asked very politely if he could have a go with my spokeshave. He sat on the shave horse and soon was making nice crisp shavings so I let him have a go with the draw knife too, (showing him first how it was safe despite cutting towards yourself) I showed how it could remove great swathes of wood, or finely scrape off wafer thin shavings.
They all wanted a go but some were too small. (Their parents were close at hand).
One of them who had been V noisy and had previously asked me why I do it, was enthralled when he had a go. So I said 'You can see why I do it now?'
It made me smile when it was time for them to go, they all thanked me and the noisey one invited me to his Birthday party! (I gracefully declined).
It just shows that it's not the kids who are uninterested in 'doing stuff' and real learning... it's just too much like hard work to do in class and we are swamped with 'health and safty' nonsense.
Del

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