Level 3 City & Guilds NVQ in Mechanical manufacturing ... · Level 3 NVQ in Mechanical Manufacturing Engineering ... Honing and Lapping Mach ines ... using Honing and Lapping Machines

Level 3 City & Guilds NVQ in Mechanical manufacturing engineering

www.city-and-guilds.co.ukJune 2004

Scheme Handbook1682

City & Guilds is the UK’s leading provider of vocational qualifications, offering over 500 awards across a wide range of industries, and progressing from entry level to the highest levels of professional achievement. With over 8500 centres in 100 countries, City & Guilds is recognised by employers worldwide for providing qualifications that offer proof of the skills they need to get the job done. The City & Guilds Group includes City & Guilds Pitman Qualifications, specialising in IT, office-based qualifications and English as a second language awards, and ILM (the Institute of Leadership & Management) providing management qualifications, learning materials and membership services. Land based qualifications are offered through NPTC, also part of the City & Guilds Group. City & Guilds also manages the Engineering Council Examinations on behalf of the Engineering Council. General information about City & Guilds is available on our website www.city-and-guilds.co.uk or from our Customer Relations team at the address below or by phoning 020 7294 2800 or e-mailing [email protected] & Guilds fully supports the principle of equal opportunities and we are committed to satisfying this principle in all our activities and published material. A copy of our equal opportunities policy statement ‘Access to assessment’ is available on our website or from the Customer Relations team.City & Guilds publications are available from our Publication Sales department at the address below or by phoning 020 7294 2850 or faxing 020 7294 3387

First published 2004©2004 The City and Guilds of London Institute All rights reserved.City & Guilds is a trademark of the City and Guilds of London Institute.Every effort has been made to ensure that the information contained in this publication is true and correct at the time of going to press. However, City & Guilds’ products and services are subject to continuous development and improvement and the right is reserved to change products and services from time to time. City & Guilds cannot accept liability for loss or damage arising from the use of information in this publication.City & Guilds1 Giltspur StreetLondon, EC1A 9DDT +44 (0)20 7294 2468F +44 (0)20 7294 2400www.city-and-guilds.co.uk

Contents Page

Foreword 3

Scheme information 4

Level 3 NVQ in Mechanical Manufacturing EngineeringQualification structure

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Assessment Requirements 9

Progression routes 16

National Occupational Standards and Evidence Recording Sheets 17

Key Skills Signposting 494

Further Information 501

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Foreword

This document provides details of the requirements specific to this N/SVQ qualification which includes:• the requirements for occupational competence for all those involved in

assessing performance• specific assessment requirements and • the National Occupational Standards.

It is designed to be used in conjunction with the following documents (also on the CD):the N/SVQ Candidate Guide and Logbookand the N/SVQ Centre Guide.

The guide does not contain details of centre and scheme approval - these may be found in the document: ‘Providing City and Guilds qualifications’ (stock code EN-00-1111) available free of charge from the Sales Department or your regional/national City & Guilds office (see Further information section of this document).

Details of general regulations, registration and certification procedures, including fees, are included in the City & Guilds Directory of N/SVQ Awards. This information also appears on City & Guilds web site http://www.city-and-guilds.co.uk

The following documents also include information on policy and guidance on quality assurance within NVQs and assessors and verifiers should be aware of the contents.

• City & Guilds policy document ‘Ensuring Quality’ – aimed at those involved in the assessment and verification of City & Guilds awards. Issued 3-4 times a year (available from Sales Department) NB Edition 12 – December 2001 summarises policy from all previous editions)

• Joint Awarding Body Guidance on Internal Verification of NVQs, issued November 2001, published by the DfES, also available on City & Guilds web site.

General NVQ information

Centres should refer to the City & Guilds Centre Guide for NVQs, included on this CD-ROM, for information on NVQs, the people involved, the assessment process and model recording forms.

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Level 3 NVQ in Mechanical Manufacturing Engineering

Scheme information

Scope of the awardNVQs for the engineering sector are work-based qualifications designed to reflect the roles and responsibilities of personnel within the sector.

This level 3 award is based on a mandatory and optional unit structure. The mandatory units cover those areas which have a common approach such as safety, engineering communications and team working. The optional units are combined in to ‘pathways’ which offer a choice to meet the needs of the main occupational patterns within typical manufacturing organisations.

National Occupational Standards and Key SkillsThe full National Occupational Standards and Key Skills mapping are enclosed within the CD. Centres may access whichever units are appropriate to their requirements.

Restrictions on entryThere are no restrictions on entry to this award, however candidates should not register for this award if they hold or are registered with City & Guilds or another awarding body for a similar award at the same level.

Qualification structureThe Level 3 NVQ in Mechanical Manufacturing Engineering consists of 99 units. All candidates must take the THREE core units plus a specified number of optional units from one of the seven occupational pathways to achieve the award. Additional units may be taken, for which the candidate will receive a Certificate of Unit Credit.

The certificates referred to in this guide are as follows

Level 3 NVQ in Mechanical Manufacturing Engineering (Machining)Level 3 NVQ in Mechanical Manufacturing Engineering (NC/CNC machining)Level 3 NVQ in Mechanical Manufacturing Engineering (Machine tool setting)Level 3 NVQ in Mechanical Manufacturing Engineering (Fitting and assembly)Level 3 NVQ in Mechanical Manufacturing Engineering (Pipe fitting and

assembly)Level 3 NVQ in Mechanical Manufacturing Engineering (Composite

manufacture/Polymer engineering)Level 3 NVQ in Mechanical Manufacturing Engineering (Optical engineering)

The Units have been contextualised by SEMTA from the National Engineering Competency Standards (ECS).

Mandatory units for all pathways (all three units must be completed)

Unit 1: Complying with Statutory Regulations and Organisational Safety Requirements Unit 2: Using and interpreting Engineering Drawings and DocumentsUnit 3: Working Efficiently and Effectively in Engineering

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Pathways (One pathway must be completed)

Machining

Must complete ONE pair of the following units:

Unit 4: Setting Centre Lathes for Production Unit 5: Machining Components using Centre Lathes

Unit 6: Setting Turret Lathes for ProductionUnit 7: Machining Components using Turret Lathes

Unit 8: Setting Milling Machines for Production Unit 9: Machining Components using Milling Machines

Unit 10: Setting Shaping, Planing or Slotting Machines for Production Unit 11: Machining Components using Shaping, Planing or Slotting Machines

Unit 12: Setting Gear Cutting Machines for ProductionUnit 13: Machining Components using Gear Cutting Machines

Unit 14: Setting Gear Grinding Machines for Production Unit 15: Machining Components using Gear Grinding Machines

Unit 16: Setting Horizontal Boring Machines for ProductionUnit 17: Machining Components using Horizontal Boring Machines

Unit 18: Setting Vertical Boring Machines for ProductionUnit 19: Machining Components using Vertical Boring Machines

Unit 20: Setting Electro Discharge Machines for ProductionUnit 21: Machining Components using Electro Discharge Machines

Unit 22: Setting Grinding Machines for ProductionUnit 23: Machining Components using Grinding Machines

Unit 24: Setting Honing and Lapping Machines for ProductionUnit 25: Machining Components using Honing and Lapping Machines

Unit 26: Setting Broaching Machines for ProductionUnit 27: Machining Components using Broaching Machines

Unit 28: Setting Metal Spinning Machines for ProductionUnit 29: Producing Components using Metal Spinning Machines

NC/CNC Machining

Must complete ONE of the following units:

Unit 30: Loading and Proving NC/CNC Machine Tool Programs Unit 31: Carrying Out CNC Machine Tool Programming

Plus ONE pair of units from the following:Unit 32: Setting NC/CNC Turning Machines for ProductionUnit 33: Machining Components using NC/CNC Turning Machines

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Unit 34: Setting NC/CNC Milling Machines for ProductionUnit 35: Machining Components using NC/CNC Milling Machines

Unit 36: Setting NC/CNC Grinding Machines for ProductionUnit 37: Machining Components using NC/CNC Grinding Machines

Unit 38: Setting NC/CNC Punching Machines for ProductionUnit 39: Machining Components using NC/CNC Punching Machines

Unit 40: Setting NC/CNC Laser Profiling Machines for Production Unit 41: Machining Components using NC/CNC Laser Profiling Machines

Unit 42: Setting NC/CNC Electro Discharge Machines for ProductionUnit 43: Machining Components using NC/CNC Electro Discharge Machines

Unit 44: Setting NC/CNC Vertical Boring Machines for Production Unit 45: Machining Components using NC/CNC Vertical Boring Machines

Unit 46: Setting NC/CNC Horizontal Boring Machines for ProductionUnit 47: Machining Components using NC/CNC Horizontal Boring Machines

Unit 48: Setting NC/CNC Gear Cutting Machines for Production Unit 49: Machining Components using NC/CNC Gear Cutting Machines

Unit 50: Setting NC/CNC Machining Centres for ProductionUnit 51: Machining Components using NC/CNC Machining Centres

Machine Tool Setting

Must complete the following unit:

Unit 52: Handing Over Machine Tools to Production Operators

Plus ONE more unit from the following:

Unit 53: Setting Capstan and Turret Lathes for ProductionUnit 54: Setting Single-Spindle Automatic Turning Machines for ProductionUnit 55: Setting Multi-Spindle Automatic Turning Machines for ProductionUnit 56: Setting Single and Multi-Spindle Drilling Machines for ProductionUnit 57: Setting Tool and Cutter Grinding Machines for ProductionUnit 58: Setting Special-Purpose Machines for ProductionUnit 59: Setting Power Presses for ProductionUnit 8: Setting Milling Machines for ProductionUnit 22: Setting Grinding Machines for ProductionUnit 10: Setting Shaping, Planing or Slotting Machines for ProductionUnit 12: Setting Gear Cutting Machines for ProductionUnit 14: Setting Gear Grinding Machines for Production Unit 20: Setting Electro Discharge Machines for Production Unit 22: Setting Grinding Machines for ProductionUnit 24: Setting Honing and Lapping Machines for ProductionUnit 26: Setting Broaching Machines for ProductionUnit 32: Setting NC/CNC Turning Machines for productionUnit 34: Setting NC/CNC Milling Machines for ProductionUnit 36: Setting NC/CNC Grinding Machines for ProductionUnit 38: Setting NC/CNC Punching Machines for ProductionUnit 40: Setting NC/CNC Laser Profiling Machines for Production

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Unit 42: Setting NC/CNC Electro Discharge Machines for ProductionUnit 48: Setting NC/CNC Gear Cutting Machines for Production Unit 50: Setting NC/CNC Machining Centres for Production

Fitting and Assembly

Must complete THREE of the following units:

Unit 60: Producing Components using Hand Fitting Techniques Unit 61: Assembling Mechanical ProductsUnit 62: Producing Components by Manual Machining Unit 63: Fitting Fluid Power Components to Mechanical AssembliesUnit 64: Fitting Pipework Systems to Mechanical AssembliesUnit 65: Fitting Electrical/Electronic Components to Mechanical AssembliesUnit 66: Producing Power Turbine Combustion AssembliesUnit 67: Producing Power Turbine Compressor AssembliesUnit 68: Producing Turbine AssembliesUnit 69: Producing Power Turbine Gearbox AssembliesUnit 70: Producing Power Turbine Major AssembliesUnit 71: Producing Piston Engine AssembliesUnit 72: Repairing and Modifying Mechanical AssembliesUnit 73: Checking Completed Assemblies Comply with Specification

Pipe Fitting and Assembly

Must complete one unit from the following: Unit 74: Pipe Bending and Forming by Hand MethodsUnit 75: Pipe Bending and Forming using Bending MachinesPlus TWO units from the following Unit 76: Assembling Screwed Pipework Unit 77: Assembling Small Bore Non-Ferrous PipeworkUnit 78: Assembling Non-Metallic PipeworkUnit 79: Preparing and Testing Pipework SystemsUnit 80: Producing Socket and Flange Fillet Welded Joints in Pipe using a Manual Welding

Process

Composite Manufacture/Polymer Engineering

Must complete ONE of the following units:Unit 81: Producing Composite Mouldings using Pre-Preg Laminating TechniquesUnit 82: Producing Composite Mouldings using Wet Lay-up TechniquesUnit 83: Producing Composite AssembliesPlus ONE unit from the following:Unit 81: Producing Composite Mouldings using Pre-Preg Laminating TechniquesUnit 82: Producing Composite Mouldings using Wet Lay-up TechniquesUnit 83: Producing Composite AssembliesUnit 84: Bonding Composite Mouldings Unit 85: Repairing Composite MouldingsUnit 86: Applying Finishes to Composite MouldingsUnit 87: Trimming Composite Mouldings using hand ToolsUnit 88: Identifying Defects in Composite MouldingsNote: Two different units must be selected

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Optical Engineering

Must complete the following unit:Unit 89: Inspecting Optical Components Plus FOUR units from the following:Unit 90: Machining Infra-red/Special Material Lenses Unit 91: Machining Optical Glass Lenses Unit 92: Machining Optical Prism and Flat ComponentsUnit 93: Setting CNC Aspheric Glass and Diamond Turning MachinesUnit 94: Machining Components using CNC Aspheric Glass and Diamond Turning

MachinesUnit 95: Setting NC/CNC Optical Grinding and Polishing Machines for ProductionUnit 96: Machining Components using NC/CNC Optical Grinding and Polishing MachinesUnit 97: Machining Optical Cylinders and DomesUnit 98: Vacuum Coating Optical MaterialsUnit 99: Machining Optical Plastic Components

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Assessment Requirements for Awards within the Engineering Sector

Introduction

The purpose of the assessment strategy is to

• assist assessors, internal verifiers and external verifiers• encourage and promote consistent assessment of the qualification• promote cost effective assessment strategies• promote the use of external quality control of assessment methods

The assessment strategy also specifies

• the qualifications and experience required for assessors and verifiers• the assessment environment and standard of equipment that should be used• access to the qualification• the evidence required to support competent performance against the standards• carrying out assessments• assessing knowledge and understanding

Section A General Requirements

The assessment strategy for City and Guilds awards based on SEMTA units is detailed below. It applies throughout the standards and must be used as the basis for all individual assessments. In the implementation of all SEMTA standards, reference should be made back to this strategy when specifying the assessment requirements for each unit or element of competence. The internal and external verifier will seek evidence that the requirements have been fulfilled by candidates and assessors at all times.

Scope of the Award

Evidence of competence must be assessed against the requirements of the relevant National Occupational Standards. For this award, the relevant standards are contextualised versions of the Engineering Competence Standards (ECS).

Qualification Structure

The qualification structure for this award requires candidates to complete common mandatory units, followed by a choice of pathways. Candidates may then be required to complete further mandatory units within their chosen pathway, followed by a number of optional units from a provided selection. The range of optional units allows for any variations in the occupation in different organisations and across the sector.

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Assessor Requirements

Assessment must be carried out by competent assessors who hold, or are working towards, the nationally recognised Assessor units (A1/A2) (formerly D32/D33).

Assessors must be able to demonstrate that they have sufficient technical competence to evaluate and judge evidence for this award. This will be demonstrated either by holding a relevant technical qualification or by proven suitable experience of the technical areas to be assessed. The assessor’s competence must, at the very least, be at the same level as that required of the candidate(s) in the units being assessed.

Specific technical requirements for assessors of this qualification are outlined on page 12.

Assessors must also know:

• the content and meaning of the National Occupational Standards against which assessments are to be carried out

• the appropriate Regulatory Body’s system of vocational qualifications• the relevant Awarding Body’s documentation and system of vocational qualifications

within which the assessment is taking place.

Verifier Requirements

Internal Verifiers must hold, or be working towards, the nationally recognised Internal Verifier unit (V1) (formerly D34), and would be expected to be familiar with, and preferably hold, the nationally recognised Assessor units.

External Verifiers must hold, or be working towards, the nationally recognised External Verifier unit (V2) (formerly D35), and would be expected to be familiar with, and preferably hold, the nationally recognised Assessor units, and possibly even the nationally recognised Internal Verifier unit.

Verifiers, both internal and external, will also be expected to be fully conversant with the standards against which the assessments and verification are to be carried out, the appropriate Regulatory Body’s system of vocational qualifications, and the relevant Awarding Body’s documentation and system of vocational qualifications within which the assessment and verification is taking place.

Additionally verifiers, both internal and external, should be technically familiar with the skill area being verified.

Specific technical requirements for verifiers of this qualification are outlined on page 13.

Witness testimony

Where observation of process is used to obtain the performance evidence, this observation must be carried out against the standards. Best practice would require that such observation is carried out by a qualified assessor. If this is not practicable then alternative sources of evidence may be used.

For example, the observation may be carried out against the standards by someone else in close contact with the candidate. This could be a supervisor, colleague, mentor or manager, who may be regarded as a suitable witness to the candidate’s competency. However, the witness must be technically competent in the process or skills that they are providing testimony for to at least the same level of expertise as thatrequired of the candidate. It will be the responsibility of the assessor to make sure that any witness testimonies accepted as evidence of a candidate’s competency are reliable and technically valid.

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Assessment Environment

Evidence for this award should be obtained from the working environment where the work activities or work outcomes to be assessed are clearly attributable to the candidate. However, in certain circumstances, replication of work activities may be acceptable.Where replication is considered necessary, assessors must be confident that the environment replicates the workplace to such an extent that competencies gained will be fully transferable to the workplace. In this case assessors must clearly identify those aspects of the workplace that are critical to performance, and make sure that they have been replicated satisfactorily. Where replication is involved, assessors must obtain agreement with internal and external verifiers before assessing any candidates.

Examples of critical aspects could be:

• environmental conditions such as, noise levels, lighting conditions and the presence of hazards

• the use of industrial equipment and procedures• pressure of work such as time constraints and repetitive activities• carrying out work on actual work pieces and the consequences of making mistakes• customer/supplier/departmental relationships

Access to Assessment

There are no entry qualifications or age limits required for these qualifications unless this is a legal requirement of the process or the environment. Assessment is open to any candidate who has the potential to reach the standards laid down for this qualification. However centres should refer to the statement on access to assessment in the City & Guilds Centre Guide for NVQs on not entering for similar awards at the same level.

Aids or appliances which are designed to alleviate disability may be used during assessment providing they do not compromise the standard required.

Carrying Out Assessments

SEMTA strongly recommends that the majority of assessment evidence for the mandatory units is gathered during the performance of the optional units. Evidence should be obtained as a whole, where practically possible, since competent performance in the optional units is often dependent on competence in the mandatory units. Although it is possible to achieve this qualification with the minimum number of optional units, organisations may wish their candidates to be assessed for more than this.

Where key skills are required, these may be included as additional units and assessed in conjunction with the mandatory and optional units, where this is appropriate.

The standards were developed to cover a range of activities. The evidence produced for this award will, therefore, depend on the candidate’s choice of ‘scope’ items in the standard, which are intended to help the candidate to seek the appropriate information and to acquire the necessary skills, techniques and knowledge before being able to demonstrate competent performance.

Where the scope section gives a choice (for example ‘any three from five’), assessors should note that candidates do not need to cover the other (in this example, two) items, particularly where these additional items may relate to other activities or methods which are not part of the candidate’s normal workplace activity or area of expertise.

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Performance Evidence Requirements

Performance evidence must be the main form of evidence gathered.

In order to demonstrate consistent, competent performance for a unit, a minimum of three different evidence examples of performance evidence will be required, to show that the tasks reflected by the unit title have been carried out to the stated standards. The number of items required in each of the scope statements specified for a unit (eg four from a choice of six) must all be covered. It is possible that some of the scope items may be covered more than once. If, however, the three examples of performance evidence are not sufficient to cover all the specified scope items, then further examples of performance evidence will be required to ensure this coverage is achieved.

Assessors must make sure that the evidence provided reflects the candidate’s competence and not just the achievement of the training programme.

Items of performance evidence often contain features that apply to more than one unit, and can be used as evidence in any unit where appropriate.

Performance evidence may be either:

• products of the candidate’s work, such as items that have been produced or worked on, documents produced as part of a work activity, records or photographs of the product

or• evidence of the way the candidates carried out the activities such as witness testimonies, assessor

observations or authenticated candidate reports of the activity undertaken

Competent performance is more than just carrying out a series of individual set tasks. Many of the units contain statements that require the candidate to provide evidence that proves they are capable of combining the various features and techniques. Where this is the case, separate fragments of evidence would not provide this combination of features and techniques and will not, therefore, be acceptable as demonstrating competent performance.

If there is any doubt as to what constitutes suitable evidence, the external verifier should be consulted.

Assessing Knowledge and Understanding

Knowledge and understanding are key components of competent performance, but it is unlikely that performance evidence alone will provide enough evidence in this area. Where the candidate’s knowledge and understanding (and the handling of contingency situations) is not apparent from performance evidence, it must be assessed by other means and be supported by suitable evidence.

Knowledge and understanding can be demonstrated in a number of different ways, but it is suggested that the most appropriate methods for this qualification are oral questioning and practicaldemonstrations. Assessors should ask enough questions to be able to determine that the candidate has an appropriate level of knowledge and understanding as required by the unit.

Where oral questioning is used the assessor must retain a record of the questions asked, together with the candidate’s answers.

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Section B Qualification-Specific Requirements for the N/SVQ in Mechanical Manufacturing Engineering Level 3

Scope of the Award

This qualification is for people who are occupied in an engineering mechanical manufacturing activity and who have a high level of technical skill and knowledge in that activity. They will be expected to demonstrate safe working practices and procedures at all times and work with minimum supervision, taking personal responsibility for the quality and accuracy of the work they carry out.

Candidates for this qualification will have gained a high level of skill ability and acquired sound knowledge and understanding of the relevant techniques, materials, tools and equipment used, in order to enable them to carry out the activities, solve related problems, correct any faults and ensure the work output meets the required specification standard.

Specific Technical Requirements for Assessors

Assessors of this qualification should have a minimum of three years’ relevant skills experience, and should have a thorough working knowledge of the processes, techniques and procedures that are used within the mechanical engineering industry.

Competence in the specific areas covered by the unit being assessed is essential.

Specific Technical Requirements for Verifiers

Verifiers should have some relevant skills experience, and should have held a position of engineering responsibility, preferably within the mechanical sector. They should have sufficient technical knowledge to enable them to verify that assessments have been carried out to the technical and safety standards required, and to be able to ask relevant questions of assessors or candidates, if deemed necessary.

Specific Evidence Requirements

Candidates must carry out at least THREE separate assessment tasks. The unit guidance and scope for each unit indicate in detail what evidence is required. There is a specific Unit Checklist provided for EACH unit in this guide.

Completing the Unit checklists

The candidate must carry out at least three separate assessment tasks. The location of all items of evidence, that must cover ALL of the criteria given in the standards, should be entered on the checklist provided after each unit under the ‘Performance Evidence’ columns. These locations must be identified in a way that allows the verifiers (internal and external) to easily trace and audit the evidence eg. Page 6 –could refer to the position in the portfolio of the inspection sheet covering a task. Drawing 1 could provide the specification for the same task. Also Job 1234 could refer to an actual product.

Note that it may not be possible to cover all of the required criteria by completing three tasks. In such cases supplementary work may be needed to cover this shortfall, this will be referenced in the fourth column.

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In addition to the unit checklist, the required evidence must also contain

• Actual product evidence where practical – eg taking into account its weight, size and or if it is an actual production item for customer use. Photographs or videos may be used in lieu provided they show the skill areas in sufficient detail for the verifiers (internal and external) to make a decision regarding the practical standards achieved

• A work sheet (company or centre devised) that clearly lays down the required product specification in terms of materials, tolerances and any time restrictions plus a drawing. Note i) it is not necessary for the candidate to personally reproduce drawings, method descriptors etc. unless these items do not exist.ii) in cases of industrial confidentiality or sensitivity then it may be permissible to exclude certain items from the evidence, but a description of the general nature of the work/activity must be provided. In cases of doubt the EV should be consulted about the validity of a proposed assessment before the candidate commences any such work.

• An inspection sheet or report that clearly identifies that the product has been reliably tested against the specification. If there are any discrepancies of a non-critical nature then the assessment may be deemed acceptable provided that there is a statement to this effect signed by a duly appointed and responsible person.

• A brief report, prepared by the candidate, that identifies any hazards or difficulties associated with the work and how these were dealt with. It should also highlight any specific requirements or special skill areas that were involved eg non standard tools, tool and work holding methods (use of jigs and fixtures etc.) Note that where relevant some aspects of this could also form part of the required knowledge evidence.

Knowledge evidence

Where the required knowledge and understanding cannot be obviously and positively inferred from an assessor or expert witness observing the practical tasks, then the candidate must be formally questioned using either short written answer or oral types of questions.The questions should only relate to the specific areas defined by the criteria for this unit, eg if only AC equipment is used then the questions should not ask for setting details etc. of DC equipment. (Note that this knowledge may well form part of an all round underpinning knowledge programme but in such cases it would be assessed separately.)

Assessors must carefully plan all types of questioning procedures beforehand. The actual questions (oral and written) must be kept under secure conditions and only made available to the candidates during the assessment process. The candidates will retain a copy of their results, including comments made by the assessor during oral questioning. (See the separate information section regarding the use of oral questioning techniques).Assessors must make the questions available to verifiers so that the latter can compare them against the results sheets held by the candidates.

The knowledge evidence should be referenced in a similar fashion to that used for performance evidence.

Note that it is not necessary to assess the knowledge criteria on three separate occasions

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NVQ in Mechanical Manufacturing Engineering Level 3 Knowledge evidence recording sheet(this should be copied for each unit)

Method(s) usedKnowledgereference Written Oral Inferred

Candidate’sEvidence location

AssessorReference

ResultDate

assessed

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3

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5

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Name Signature

Candidate: Date:

Assessor: Date:

Internal Verifier Date:

External Verifier Date:

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Engineering Sector Progression Routes

Occupational Relevant NQF Roles Qualifications Level

Director Chartered Engineer 5Senior manager Higher Hons/Hons DegreeSenior engineer Bachelors Degree/Certificate

Management N/SVQsProject manager Incorporated engineer

City & Guilds Higher level qualifications 4Product Development Accounting/Admin N/SVQsEngineer Training & Development N/SVQTechnician Business-improvement techniques NVQ

BTEC Engineering (B.Tech) HNC/HND

AMA Engineering 3Engineering NVQs

Supervisor/Leader Management N/SVQsCraftsperson Business-improvement techniques NVQProduction/Quality Controller Technical services N/SVQHealth & Safety Controller Information Technology N/SVQ

Training and Development N/SVQBTEC Engineering (B.Tech) NC/NDCity & Guilds Engineering vocational awards

FMA engineering 2City & Guilds Engineering vocational awards

Semi-skilled operative Performing engineering operations NVQBusiness-improvement techniques NVQPerforming manufacturing operations NVQ Health and Safety Certs

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Performing engineering operations NVQOperative Performing manufacturing operations NVQ

Applying engineering principles awardGCSE engineering

ENTRANTS

WITH

PRIOR

EXPERIENCE

&

QUALIFICATIONS

ENTRY LEVEL

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National Occupation Standards and assessment record sheets– Mechanical Manufacturing Engineering Level 3

Standards supplied by SEMTA

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Level 3 NVQ in Mechanical manufacturing engineering

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Unit 1 Complying With Statutory Regulations and Organisational Safety Requirements

Unit Summary

This unit identifies the competencies you need to deal with statutory and organisational safety requirements in accordance with approved regulations, codes of practice and procedures. You will be required to comply with all relevant regulations that apply to your area of work as well as your general responsibilities as defined in the Health and Safety at Work Act. You will also need to be able to identify the relevant qualified first aiders or appointed person and know the location of the first aid facilities. You will have an understanding of the procedures to be adopted in the case of accidents involving injury and in situations where there are dangerous occurrences or hazardous malfunctions of equipment, processes or machinery. You will also need to be fully conversant with the organisation’s procedures for fire alerts and the evacuation of premises.

You will also be required to identify the hazards and risks that are associated with your job. Typically these will focus on your working environment, the tools and equipment that you use, materials and substances that you use and working practices that do not follow laid down procedures, and manual lifting and carrying techniques.

Your responsibilities will require you to comply with organisational policy and procedures for the Statutory Regulations and organisational safety activities undertaken and to report any problems with the safety activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and the way in which you carry out the required engineering activities.

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying Statutory Regulations and organisational safety requirements and procedures. You will understand the safety requirements and their application, and will know about the safety requirements in adequate depth to provide a sound basis for carrying out the activities safely and correctly.


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Performance statements:

You must:a. Comply with your duties and obligations as defined in the Health and Safety at Work Act b. Present yourself in the workplace suitably prepared for the activities to be undertakenc. Follow organisational accident and emergency proceduresd. Recognise and control hazards in the workplacee. Use correct manual lifting and carrying techniquesf. Apply safe working practices and procedures

Scope of the unit:The numbers of scope items specified (below) indicate the minimum requirements for this Occupational Standard.

You must:1. Demonstrate your understanding of your duties and obligations to health and safety by carrying out all of the following:

● apply in principle your duties and responsibilities as an individual under the Health and Safety at Work Act and relevant current legislation

● identifying within your organisation, appropriate sources of information and guidance on health and safety issues, to include:

o Eye protection and personal protective equipment o COSHH regulationso Risk assessments

● identifying the warning signs and labels of the main groups of hazardous or dangerous substances● complying with the appropriate Statutory Regulations at all times

2. Comply with all emergency requirements to include:● identifying the appropriate qualified first aiders or appointed person and the location of first aid facilities● identifying the procedures to be followed in the event of injury to self or others● following organisational procedures in the event of fire and the evacuation of premises● identifying the procedures to be followed in the event of dangerous occurrences or hazardous

malfunctions3. Identify the hazards and risks that are associated with all of the following:

● your working environment ● the tools and equipment that you use ● materials and substances that you use● using working practices that do not follow laid down procedures

4. Demonstrate two methods of manual lifting and carrying techniques:lifting alone with assistance of others ● with mechanical assistance

5. Apply safe working practices in an industrial environment to include all of the following:● maintaining a tidy workplace with exits and gangways free from obstructions● using tools and equipment safely and only for the purpose intended● observing organisational safety rules, signs and hazard warnings● taking measures to protect others from harm by any work you are carrying out


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Knowledge statements:

You must have knowledge and understanding of :

1. The roles and responsibilities of yourself and others under the Health and Safety at Work Act 1974 and current legislation (eg. The Management of Health and Safety at Work Regulations; Workplace Health and Safety and Welfare Regulations; Personal Protective Equipment at Work Regulations; Manual Handling Operations Regulations; Provision and use of Work Equipment Regulations; Display Screen at Work Regulations)

2. The specific regulations and safe working practices and procedures that apply to your work activities3. The warning signs for the seven main groups of hazardous substances defined by Classification, Packaging and

Labelling of Dangerous Substances Regulations4. How to locate relevant health and safety information for your tasks and the sources of expert assistance when

help is needed5. What constitutes a hazard in the workplace (such as moving parts of machinery, electricity, slippery and uneven

surfaces, dust and fumes, handling and transporting, contaminants and irritants, material ejection, fire, working at height, environment, pressure/stored energy systems, volatile or toxic materials, unshielded processes)

6. What are your responsibilities for dealing with hazards and reducing risks in the workplace (such as hazard spotting and safety inspections; the use of hazard check lists, carrying out risk assessments, COSHH assessments and safe systems of working)

7. What are the risks associated with your working environment, the tools, materials and equipment that you use, spillages of oil and chemicals, not reporting accidental breakages of tools or equipment and not following laid down working practices and procedures

8. What first aid facilities exist within your work area and within the organisation in general and the procedures to be followed in the case of accidents involving injury

9. What constitutes dangerous occurrences and hazardous malfunctions and why these must be reported even when no one was injured

10. The procedures for sounding the emergency alarms, evacuation procedures and escape routes to be used and the need to report your presence at the appropriate assembly point

11. What the organisational policy is with regard to fire fighting procedures, the common causes of fire and what you can do to help prevent them

12. What protective clothing and equipment is available for your areas of activity13. How to safely lift and carry loads and the manual and mechanical aids available14. How to prepare and maintain safe working areas, standards and procedures to ensure good housekeeping15. The importance of safe storage of tools, equipment, materials and products16. The extent of your own responsibility and whom you should report to, in the event of problems that you cannot resolve


22

evidence record sheetperformance evidence 1

performance evidence 2


additional performance evidence (if

required)evidence typedatehealth & safety (understanding all application of duties and equipment)H & S at Work ActPPECOSHHrisk assessmentshazardous substancesstatutory regulationsemergency requirements (all)first aider/facilitiesinjury proceduresfire proceduresdanger/hazard proceduresenvironmental hazards/risks (all)working environmenttools & equipmentmaterials and substancesbad working practicesmanual lifting & carrying techniques (two)lifting alonewith assistance of otherswith mechanical assistancesafe working practices (all)tidy workplacetools & equipmentsafety/hazard warningsprotect others

Knowledge and understanding reference:

Candidate: Date:Assessor: Date:


23

Unit 2 Using & Interpreting Engineering Drawings & Documents

Unit Summary

This unit identifies the competencies you need to make effective use of text, numeric and graphical information by interpreting and using technical information extracted from engineering drawings, technical manuals, reference tables, specifications and charts in accordance with approved procedures. You will be required to extract the necessary information from the various drawings and related documents in order to establish and carry out the work requirements and to make valid decisions about the quality and accuracy of the work produced in accordance with approved procedures.

Your responsibilities will require you to comply with organisational policy and procedures for obtaining and using the drawings and related specifications. You will be expected to report any problems with the use and interpretation of the drawings and specifications that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of the types of drawings and documents used and provide an informed approach to applying instructions and procedures. You will be able to read and interpret the drawings and documents used and will know about the conventions, symbols and abbreviations in adequate depth to provide a sound basis for carrying out the activities to the required specification.


24

Unit 2 Using & Interpreting Engineering Drawings & DocumentsPerformance statements:

You must:a. Use the approved source to obtain the required drawings and specificationsb. Correctly interpret the drawings and specificationsc. Identify, extract and interpret the required informationd. Use the information obtained to ensure that work output meets the specificatione. Deal promptly and effectively with any problems within your control and report those which cannot be solvedf. Report any inaccuracies or discrepancies in drawings and specifications


You must: 1. Use approved sources to obtain the necessary drawings and related specifications and carry out all of the following:

● check the currency and validity of the drawings and documents used● exercise care and control over the documents at all times● correctly extract all necessary data in order to carry out the required tasks● seek out additional information where there are gaps or deficiencies in the information obtained● deal with or report any problems found with the drawings/specifications● make valid decisions based on the evaluation of the engineering information gained● return all drawings and related specifications to the approved location on completion of the work● complete all necessary production documentation

2. Use information extracted from engineering drawings to include one or more types of drawing from the following:

● detailed component drawings● general assembly drawings● repair drawings ● fluid power drawings● wiring/circuit diagrams ● installation drawings

● modification drawings● sub-assembly drawings● schematic diagrams● fabrication drawings ● welding drawings

3. Use information extracted from related documentation to include two from the following:● job instructions● drawing instructions● test schedules● manufacturers instructions● weld procedure specifications

● reference tables/charts● national, international and organisational standards● planning documentation● quality control documents

4. Extract information that includes three of the following: ● materials or components required● dimensions● tolerances ● build quality

installation requirements

● surface texture requirements ● location/orientation of parts● process or treatments required● assembly sequence

● weld type and size● operations required ● connections to be made

● circuit characteristics (such as pressure, flow, current, voltage, speed)


25

Unit 2 Using & Interpreting Engineering Drawings & DocumentsKnowledge statements:

You must have knowledge and understanding of:

1. The information sources used for the drawings and specifications that you use in your work activities2. How drawings and documents are obtained and how to check that they are current and valid3. How to use other sources of information to support the drawings (such as electronic component pin

configuration specifications, standard reference charts for limits and fits, tapping drill reference charts, bend allowances required for material thickness, electrical conditions required for specific welding rods)

4. The procedures for reporting discrepancies in the drawings or documents and for reporting lost or damaged drawings/documents

5. Care and control procedures for the drawings and documents and the importance of returning them to the designated location on completion of the work activities

6. The basic drawing conventions that are used and why there needs to be different types of drawings7. The types of drawings used and how they interrelate (such as isometric and orthographic, first and third angle,

assembly drawings, circuit and wiring diagrams, block and schematic diagrams)8. Imperial and metric systems of measurement, tolerancing and fixed reference points9. The meaning of the different symbols and abbreviations found on the drawings that you use (such as surface

finish, electronic components, weld symbols, linear and geometric tolerances, pressure and flow characteristics)10. Care and control procedures for drawings and specifications and how damage or graffiti on drawings can lead to

scrapped work 11. The extent of your own responsibility, when to act on your own initiative to find, clarify and evaluate information

and whom you should report to if you have problems that you cannot solve


26

evidence record sheet performance evidence 1




required)evidence typedatenecessary drawings & specifications (all)check currency & validitycare & controlextract dataadditional informationproblemsdecisionsreturn drawings etcproduction documentationinformation extracted from engineering drawings (one or more)componentassemblyrepairfluid powerwiring/circuitinstallationmodificationsub-assemblyschematicfabricationweldinginformation extracted from related documentation (two)job instructionsdrawing instructionstest schedulesmanufacturers instructionsweld procedure spec’sreference tables/chartsstandardsplanning docsquality control docsextract information (three)materials/componentsdimensionstolerancesbuild qualityinstallationcircuit characteristicssurface texturelocation/orientation of partsprocess or treatmentsassembly sequenceweld type/sizeoperationsconnections




27

Unit 3 Working Efficiently & Effectively in Engineering

Unit Summary

This unit identifies the competencies you need to work efficiently and effectively in the work place in accordance with approved procedures and practices. Prior to undertaking the engineering activity you will be required to carry out all necessary preparations within the scope of your responsibility. This may include preparing the work area and ensuring that it is in a safe condition to carry out the intended activities, ensuring you have the appropriate job specifications and instructions, that any tools, equipment, materials and other resources required are available and in a safe and usable condition.

On completion of the engineering activity you will be required to return your immediate work area to an acceptable condition before recommencing further work requirements. This may involve placing completed work in the correct location, return and / or store any tools and equipment in the correct area, identifying any waste and / or scrapped materials and arranging for their disposal, reporting any defects or damage to tools and equipment used.

In order to be efficient and effective in the workplace you will also be required to demonstrate that you can create and maintain effective working relationships with colleagues and line management, review objectives and targets for your personal development, contribute to and communicate any opportunities for improvements that could be made to working practices and procedures.

Your responsibilities will require you to comply with organisational policy and procedures for the engineering activities undertaken and to report any problems with the activities, or the tools and equipment that are used that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to take personal responsibility for your own actions and the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to working efficiently and effectively in an engineering environment. You will understand the need to work efficiently and effectively and its application, and will know about the areas you need to consider when preparing and tidying up the work area, how to contribute to improvements, deal with problems, maintain effective working relationships and agree your development objectives and targets in adequate depth to provide a sound basis for carrying out the activities safely and correctly. You will understand the safety precautions required when carrying out engineering activities. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.


28

Unit 3 Working Efficiently & Effectively in EngineeringPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Prepare the work area to carry out the engineering activityc. Check there are sufficient supplies of materials and/or consumables and that they meet work requirementsd. Ensure completed products or resources are stored in the appropriate location on completion of the activitiese. Tidy up the work area on completion of the engineering activityf. Deal promptly and effectively with problems within you control and report those that cannot be resolvedg. Contribute and communicate opportunities for improvement to working practices and procedures h. Maintain effective working relationships with colleaguesi. Review personal training and development as is appropriate to the job role

Scope of the unit:The numbers of scope items specified (below) indicate the minimum requirements for this Occupational Standard.You must:1. Prepare to carry out the engineering activity taking into consideration all of the following as is applicable to

the work to be undertaken:• the work area is free from hazards and suitably prepared for the activities to be undertaken • any required safety procedures are implemented• any necessary personal protection equipment is obtained and is in a usable condition• tools and equipment required are obtained and checked that they are in a safe and useable condition• all necessary drawings, specifications and associated documentation is obtained• job instructions are obtained and understood• the correct materials or components are obtained • storage arrangements for work are appropriate• appropriate authorisation to carry out the work is obtained

2. Complete work activities to include all of the following:● completing all necessary documentation accurately

and legibly● returning tools and equipment ● returning drawings and work instructions

● identifying where appropriate any unusable tools, equipment and components

● arranging for disposal of waste materials

3. Contribute to organisational procedures for identifying opportunities for improvement to one of the following:● working practices● working methods● quality● safety

● tools and equipment● suppliers● internal communication● customer service

● training and development● teamwork● other

4. Deal with problems affecting the engineering process to include two of the following:● materials● tools and equipment● drawings

● job specification● quality● people

● timescales● safety● activities or procedures

5. Maintain effective working relationships to include two of the following:● colleagues within own working group● colleagues outside normal working group

● line management● external contacts

6. Review personal development objectives and targets to include one of the following:● dual or multi skilling● training on new equipment/technology● increased responsibility

● understanding of company working practices, procedures, plans and policies

● other specific requirements


29

Unit 3 Working Efficiently & Effectively in EngineeringKnowledge statements:

You must have a knowledge and understanding of:

1. The safe working practices and procedures to be followed whilst preparing and tidying up your work environment2. The correct use of any equipment used to protect the health and safety of you and your colleagues3. The procedure for ensuring that all documentation relating to the work being carried out is available and current

prior to starting the activity4. The action that should be taken if documentation received is incomplete and / or incorrect5. The procedure for ensuring all tools and equipment are available prior to undertaking the activity6. The checks to be carried out to ensure tools and equipment are in full working order prior to undertaking the

activity7. The action that should be taken if tools and equipment are not in full working8. The checks to be carried out to ensure all materials required are correct and complete prior to undertaking the

activity9. The action that should be taken if materials do not meet the requirements of the activity10. Who to inform when the work activity has been completed11. The information and / or documentation they require to confirm the activity has been completed12. What materials, equipment and tools can be re-used13. How any waste materials and / or products are transferred, stored and disposed of14. Where tools and equipment should be stored and located15. The importance of making a contribution to improving working practices16. The procedure and format for making suggestions for improvements17. What the benefits are to you and the organisation if improvements can be identified18. The importance of maintaining effective working relationships within the workplace19. The procedures to deal with and report any problems that can affect working relationships20. The type of difficulties that can occur in working relationships21. The regulations that affect how you should be treated at work (such as Equal Opportunities Act, Race and Sex

Discrimination, Working Time Directive)22. The benefits of continuous personal development23. The training opportunities that are available in the workplace24. The importance of why your training and development should be reviewed25. Who to discuss training and development issues with26. The extent of your own responsibility and whom you should report to if you have any problems that you cannot

resolve


30




additional performance

evidence (if required)evidence typedatepreparation for engineering activity (all)work area free of hazardssafety proceduresPPEtools/equipmentdrawings/specs/docsjob instructionsmaterials/componentsstorageauthorisationwork activities (all)necessary docsreturn tools/equipmentreturn drawingsunusable tools/componentswaste materialsidentify opportunities for improvement (one)working practicesworking methodsqualitysafetytools/equipmentsuppliersinternal communicationcustomer servicetraining/developmentteamworkotherdeal with problems affecting engineering process (two)materialstools/equipmentdrawingsjob specificationqualitypeopletimescalessafetyactivities/proceduresmaintain effective working relationships (two)own working groupoutside own working groupline managementexternal contacts


31





evidence (if required)evidence typedatepersonal development objectives (one)dual or multi-skillingnew equipment/ technologyresponsibilitycompany working policiesother




32

Unit 4: Setting Centre Lathes for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up centre lathes, in accordance with approved procedures. This will involve selecting the appropriate workholding devices, securing them to the machine spindle, selecting and setting suitable chuck jaws or collets, boring out soft jaws, setting workpieces mounted between centres, mounting workpieces in jigs/fixtures or setting workpieces on face plates in the correct relationship to the machine spindle. You will be expected to select the appropriate turning tools, check that they are in a usable condition and mount and secure them to the relevant tool holding devices.

You will need to set the machine operating parameters to produce the workpiece to the required specification. This will involve setting feeds and speeds, setting roughing and finishing cuts and using accessories such as taper turning attachments, profiling attachments, offsetting the tailstock, angular setting of compound slide, and the setting and adjusting of change gears for screw cutting. You must produce trial cuts and prove the machine is working satisfactorily before declaring the machine ready for production. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.

Your responsibilities will require you to comply with organisational policy and procedures for the machine setting activities undertaken, and to report any problems with the machine, tooling, equipment or setting up activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting up procedures used. You will understand the machine used, and its application, and will know about the workholding devices, turning tools, relevant materials, consumables and setting up procedures, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the work output is to the required specification.

You will understand the safety precautions required when working with the machines and their associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

This unit does not cover CNC turning activities, for which other units apply.


33

Unit 4: Setting Centre Lathes for ProductionPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the correct specifications for the component to be producedc. Determine what has to be done and how the machine will be set to achieve thisd. Mount and set the required work-holding devices, work piece and cutting toolse. Set the machine tool operating parameters to achieve the component specificationf. Check that all safety mechanisms are in place and that the equipment is set correctly for the required operationsg. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must:1. Carry out all the following activities during setting up:● ensure correctly adjusted machine guards are in place● check cutting tools are in a suitable condition

● hold components securely without distortion● apply safe working practices at all times

2. Select, mount and secure the workpiece using four of the following workholding devices:● chucks with hard jaws● chucks with soft jaws● collet chucks

● drive plate and centres ● fixtures ● faceplates

● magnetic or pneumatic devices● fixed steadies or traveling steadies● four jaw chucks

3. Use two of the following groups of turning tools: ● solid high speed steel ● brazed tungsten carbide indexible tips (carbide, ceramic, diamond)4. Select and mount the following types of lathe tools to include eight of:● turning● facing● boring

● knurling● parting off ● forming

● recessing ● chamfering● centre drills

● twist/core drills● reamers ● taps

● thread chaser● single point threading

5. Use two of the following taper turning or profiling methods:● taper turning attachment● form tools

profiling attachment offset tailstock compound slide

6. Set the machine parameters in accordance with instructions/specifications to include all of the following:● position of workpiece● position of turning tools in relationship to workpiece● mechanisms (threading, profiles, taper)● workpiece revolutions per minute

● linear feed rate ● depth of cut for roughing and finishing● cutting fluid flow rate● machine guards and safety mechanisms

7. Set up the machine to produce internal and external profiles that includes ten of the following:● flat faces ● parallel diameters● stepped diameters● tapered diameters

● drilled holes● bored holes● reamed holes ● profile forms

● internal threads● external threads● eccentric features● parting off

● chamfers ● knurls or special finishes● grooves● undercuts

8. Machine components made from one of the following types of material:● ferrous ● non-metallic ● non-ferrous

9. Make trial components to prove the machine is operating to required specification, to include all the following:● components to be free from false tool cuts, burrs and sharp edges● dimensional tolerance equivalent to BS 4500 or BS 1916 Grade 7● surface finish 63 µin or 1.6µm ● reamed and bored holes within H8

● screw threads BS medium fit● angles within +/- 0.5 degree


34

Unit 4: Setting Centre Lathes for ProductionKnowledge statements:


1. The specific safety precautions to be taken when setting up workholding devices and accessories, workpiece and turning tools on lathes

2. The hazards associated with lathes (moving parts of machinery, handling turning tools, handling cutting fluids, airborne particles, tool breakage, insecure components) and how they can be minimised

3. How to stop the machine in both normal and emergency situations, and the procedure for restarting after an emergency

4. The importance of ensuring the machine is isolated from the power supply before mounting turning tools and workholding devices

5. The importance of wearing the appropriate protective clothing and equipment, and of keeping the work area clean and tidy

6. The basic principles of operation of the centre lathe and its accessories, and typical operations that they can perform7. How to handle and store turning tools safely and correctly8. How to use and extract information from engineering drawings and related specifications, to include symbols and

conventions to appropriate BS or ISO standards in relation to work undertaken9. How to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference

points and system of tolerancing10. Terminology used in turning in relation to the activities undertaken11. The range of workholding methods and devices that are used on centre lathes (two, three and four jaw chucks, collet

chucks, jigs and fixtures, face plates, drive plate and centres)12. The methods of mounting and setting the workpiece in/on the workholding devices, and the tools and equipment

that can be used13. The different types of turning tools that are used, and how they are selected, prepared and mounted to the machine

tool holding devices (front tool box, rear tool box, tailstock)14. Factors which determine speeds and feeds to be used (material, type of tooling, depth of cut, workpiece rigidity,

machine condition, tolerance and finish required)15. How the various types of material will affect the feeds and speeds that can be used16. The type of cutting fluids that are used, and precautions to be taken when handling and using them17. How to set up the centre lathe and its accessories for the particular operations being performed18. The need to conduct trial runs and check that the machine is set up and producing the components correctly19. Problems that can occur with setting up the workholding devices, tooling and machine operating parameters, and

what to do if problems occur20. The extent of your own authority and whom you should report to when you have problems you cannot resolve


35





required)evidence typedate carry out activities during setting up (all)machine guards in place and correctly adjustedcomponents held securelycutting tools in suitable condition safe working practicesuse workholding devices ( four)hard jaw chucksoft jaw chuckcollet chuckdrive plate and centresfixturesfaceplatesmagnetic/pneumaticfixed/travelling steadiesfour jaw chuckuse turning tools (two)solid high speed steelbraze tungsten carbideindexible tipsselect and mount lathe tools (eight)turningfacingboringknurlingparting offformingrecessingchamferingcentre drillstwist/core drillsreamerstapsthread chasersingle point threadinguse taper turning or profiling methods (two)taper turning attachmentform toolsprofiling attachmentoffset tailstockcompound slide


36





required)evidence typedate set machine parameters according to instructions/specification (all)position of workpieceposition of turning toolsmechanismsworkpiece rev/minlinear feed ratedepth of cutcutting fluid flow ratemachine guardsset up machine to produce internal and external profiles (ten)flat facesparallel diametersstepped diameterstapered diameters drilled holesbored holesreamed holesprofile formsinternal threadsexternal threadseccentric featuresparting offchamfersknurls/special finishesgroovesundercutsmachine components from materials(one)ferrousnon-ferrousnon-metallicmake trial components to specification (all)free from false tool cuts, burrs or sharp edgesdimensional tolerance BS4500 or BS 1916 grade 7surface finish 63µin or 1.6µmscrew threads BS medium fitreamed & bored holes within H8

angles ± 0.5 degree


Candidate: Date:

Assessor: Date:


37

Unit 5: Machining Components using Centre Lathes

Unit Summary

This unit identifies the competencies you need to carry out turning operations on a centre lathe, in accordance with approved procedures. You will be required to check that the machine is ready for the operations to be performed, and that all the required components/materials and consumables are available. You will be expected to produce a range of components that combine a number of different features, such as parallel, stepped and tapered diameters, drilled, bored and reamed holes, internal and external threads, and special forms/profiles.

You will be required to operate the machine in line with safe working practices and approved procedures, and to continuously monitor the machining operations, making any necessary adjustments in order to ensure that the work output is to the required quality and accuracy. Meeting production targets will be an important issue, and your production records must show consistent and satisfactory performance.

Your responsibilities will require you to comply with organisational policy and procedures for the machining activities undertaken, and to report any problems with the machining activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying machining procedures. You will understand the centre lathe turning process, and its application, and will know about the equipment, materials and consumables, in adequate depth to provide a sound basis for carrying out the activities to the required specification.

You will understand the safety precautions required when working with the machine and its associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

Setting up of the machine, its tooling and associated workholding devices, is the subject of another unit.


38

Unit 5: Machining Components using Centre LathesPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Confirm that the machine is set up and ready for the machining activities to be carried out c. Manipulate the machine tool controls safely and correctly in line with operational procedures d. Produce components to the required quality and within the specified dimensional accuracye. Carry out quality sampling checks at suitable intervals f. Deal promptly and effectively with problems within your control and report those that cannot be solvedg. Shut down the equipment to a safe condition on conclusion of the machining activities


You must:1. Ensure that you apply all the following checks and practices at all times during the machining activities:

• machine guards are in place and correctly adjusted• components are held securely without distortion• cutting tools are maintained in a suitable condition• safe working practices are observed• machine settings are adjusted as required to maintain the required accuracy• components produced meet specification

2. Produce machined components which combine different operations and cover ten of the following: ● flat faces ● parallel diameters● stepped diameters● tapered diameters



● chamfers ● knurls or special finishes● grooves● undercuts

3. Machine components made from one of the following types of material:● ferrous● non-ferrous● non-metallic

4. Produce components within all of the following quality and accuracy standards applicable to the operation:● components to be free from false tool cuts, burrs and sharp edges● dimensional tolerance equivalent to BS 4500 or BS 1916 Grade 7● surface finish 63 µin or 1.6µm ● reamed and bored holes within H8● screw threads BS medium fit● angles within +/- 0.5 degree

5. Carry out the necessary checks for accuracy during production of at least five of the following: ● diameters● hole size/fit● surface finish● angle● taper

● thread profile and fit● lengths● depths● concentricity● grooves/undercut


39

Unit 5: Machining Components using Centre LathesKnowledge statements:


1. The safe working practices and procedures that need to be followed while operating centre lathes2. The safety mechanisms on the machine, and the procedure for checking that they function correctly3. Operation of the machine controls in both hand and power modes4. How to stop the machine in both normal and emergency situations, and the procedure for restarting after an

emergency5. The personal protective equipment that needs to be worn, and where this can be obtained6. The hazards associated with the turning operations, and how they can be minimised7. The importance of keeping the work area clean and tidy8. Where to obtain the component drawings, specifications and/or job instructions required for the components to be

machined9. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing11. The main features of the centre lathes and the accessories that can be used (saddle, compound slide, tailstock,

taper turning attachments, profile attachments, fixed and travelling steadies)12. The various turning operations that can be performed, and the shapes and types of tooling that can be used (solid

high speed tooling, brazed tip tooling, interchangeable tipped tooling)13. The methods that can be used to position the tooling in relationship to the workpiece14. The effects of backlash in machine slides and screws, and how this can be overcome15. How to handle and store tools safely and correctly16. Factors which affect the selection of cutting feeds and speeds, and the depth of cut that can be taken17. How the various types of material will affect the feeds and speeds that can be used18. The application of roughing and finishing cuts, and the effect on tool life, surface finish and dimensional accuracy19. The application of cutting fluids with regard to a range of different materials20. The effects of clamping the workpiece in a chuck/work holding device, and how this can cause distortion in the

finished components21. How to recognise machining faults and identify when tools need re-sharpening22. The quality control procedures used, inspection checks that need to be carried out, and the equipment that will

need to be used23. The problems that can occur with the turning activities, and how these can be overcome24. The extent of your own authority and whom you should report to when you have problems you cannot resolve


40





required)evidence typedate apply checks and practices during machining activities (all)machine guards in place and correctly adjustedcomponents held securelycutting tools in suitable condition safe working practicesmachine settings adjustedcomponents meet specificationproduce machined components covering (ten)flat facesparallel diametersstepped diameterstapered diametersdrilled holesbored holesreamed holesprofile formsinternal threadsexternal threads eccentric features parting offchamfers knurls or special finishesgroovesundercutsmachine components (one)ferrousnon-ferrousnon metallicproduce components within quality and accuracy standards (all)free from false tool cuts, burrs or sharp edgesdimensional tolerance BS4500 or BS 1916 grade 7surface finish 63µin or 1.6µmscrew threads BS medium fitreamed & bored holes within H8angles ± 0.5 degree


41





required)evidence typedate checks for accuracy during production (five)diametershole size/fitsurface finishangletaperthread profile and fitlengthsdepthsconcentricitygrooves/undercut


Candidate: Date:

Assessor: Date:


42

Unit 6: Setting Turret Lathes for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up turret lathes, in accordance with approved procedures. This will involve selecting the appropriate workholding devices, securing them to the machine spindle, selecting and setting suitable chuck jaws, boring out soft jaws and mounting workpieces in jigs or fixtures. You will be expected to select the appropriate turning tools, check that they are in a usable condition, and mount and secure them to the relevant tool holding devices in front and rear tool posts and turret head.

You will need to set the machine operating parameters to produce the workpiece to the required specification. This will involve setting up turret and saddle feed stops, setting appropriate depths of cut for roughing and finishing operations, selecting and setting feeds and speeds, setting up multiple cutting arrangements between turret and saddle, setting up accessories such as taper turning attachments, profiling attachments, and setting up lead screws and screw cutting mechanisms. You must produce trial cuts, and prove the machine is working satisfactorily before declaring the machine ready for production. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.


Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting up procedures used. You will understand the machine used, and its application, and will know about the workholding devices, turning tools, relevant materials, consumables and setting up procedures, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the work output is to the required specification.


This unit does not cover CNC turning activities, for which other units apply.


43

Unit 6: Setting Turret Lathes for Production Performance statements:



You must:1. Carry out all the following activities during setting up:

● ensure correctly adjusted machine guards are in place● check cutting tools are in a suitable condition


2. Select, mount and secure the workpiece using four of the following workholding devices:● hand chucks with hard jaws● hand chucks with soft jaws

● power chucks with hard jaws● power chucks with soft jaws

● jigs/fixtures ● collet chucks

3. Use two of the following groups of turning tools: ● solid high speed steel ● brazed tungsten carbide indexible tips (carbide, ceramic, diamond)

4. Select and mount the following types of lathe tools, to include eight of: ● turning tools● facing tools● form tools

chamfer/radii

● parting off tools● thread chaser● single point threading

boring bars

● recessing tools● center drills ● twist/core drills

solid reamers

● expanding reamers ● taps● dies

knurling tool5. Mount tools in all of the following locations:

● in front tool box● in rear tool post● vertically or tangentially in turret knee box

in boring bars (single and multiple)in chucks or floating arrangementsto produce multiple cutting arrangements

6. Set up the machine in accordance with instructions and specifications to include all of the following:● position of workpiece ● screw cutting mechanisms ● linear feed rate ● cutting fluid flow rate● position of turning tools in relationship to workpiece● workpiece revolutions per minute

● depth of cut for roughing and finishing● machine guards/safety mechanisms

7. Set up the machine to produce internal and external profiles that include ten of the following:● flat faces ● parallel diameters● stepped diameters● tapered diameters



● chamfers and radii ● knurls/special finishes● grooves/undercuts● counter bores


9. Make trial components to prove the machine is operating to required specification to include all the following:● components to be free from false tool cuts, burrs and sharp edges● dimensional tolerance equivalent to BS 4500 or BS 1916 Grade 7● surface finish 63µin or 1.6µm ● reamed and bored holes within H8

● screw threads BS medium fit● angles within +/- 0.5 degree


44

Unit 6: Setting Turret Lathes for Production Knowledge statements:


1. The specific safety precautions to be taken when setting up workholding devices and accessories, workpiece and turning tools on turret lathes

2. The hazards associated with turret (moving parts of machinery, handling turning tools, handling cutting fluids, airborne particles, tool breakage, power chucks, insecure components) lathes and how they can be minimised

3. How to start and stop the machine in normal and emergency situations4. The importance of ensuring the machine is isolated from the power supply before mounting turning tools and

workholding devices5. The importance of wearing the appropriate protective clothing and equipment, and of keeping the work area clean

and tidy6. The basic principles of operation of the turret lathe and its accessories, and typical operations that they can perform7. How to handle and store turning tools safely and correctly8. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing10. How to read and interpret drawings and extract the relevant information11. Terminology used in turret lathe turning in relation to the activities undertaken12. The range of work holding methods and devices that are used on turret lathes (two, three and four jaw chucks, hand

and power operated chucks, collet chucks, jigs and fixtures)13. The use of hard and soft jaws in chucks, and the methods of boring out soft jaws to suit the workpiece14. The different types of turning tools that are used, and how they are selected, prepared and mounted to the machine

tool holding devices (front tool box, rear tool box, turret head)15. The use of pilot bars and shoes for the turret and, why they need to be accurately aligned16. The need to produce a balanced turret arrangement with tools appropriately positioned around the turret stations17. Factors which determine speeds and feeds to be used (material, type of tooling, depth of cut, workpiece rigidity,

machine condition, multiple cutting arrangements between turret and saddle, tolerance and finish required)18. How the various types of material will affect the feeds and speeds that can be used19. The type of cutting fluids that are used, and precautions to be taken when handling and using them20. How to set up the turret lathe and its accessories for the particular operations being performed21. The need to conduct trial runs, and to check that the machine is set up and producing the components correctly22. Problems that can occur with setting up the workholding devices, tooling and machine operating parameters, and

what to do if problems occur23. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


45





required)evidence typedate carry out activities during setting up (all)machine guards in place and correctly adjustedcomponents held securelycutting tools in suitable condition safe working practicessecure workpiece devices (four)hand chucks with hard jawshand chucks with soft jawspower chucks with hard jawspower chucks with soft jawsjigs/fixturescollet chucksuse turning tools (two)Solid high speed steelbrazed tungsten carbideIndexible tipsselect and mount lathe tools to include (eight)turning tools facing toolsform toolschamfer/radiiparting off toolsthread chasersingle point threadingboring barsrecessing toolscentre drillstwist/core drillssolid reamersexpanding reamerstapsdiesknurling toolmount tools in (two)front tool boxrear tool postturret knee box vertically/tangentially boring bars (single/multiple)chucks or floating arrangementsmultiple cutting arrangements


46





required)evidence typedate set up machine in accordance with instructions and specifications (all)position of workpieceposition of turning toolsworkpiece rev/minscrew cutting mechanismlinear feed ratedepth of cut roughing/finishingmachine guards/safety mechanismcutting fluid flow rateset up machine to produce internal/external profiles (ten)flat facesparallel diametersstepped diameters tapered diametersdrilled holesbored holesreamed holesprofile formsinternal threads external threads eccentric featuresparting offchamfers and radiiknurls/special finishesgrooves/undercutscounter boresmachine components from (one)ferrousnon-metallicnon ferrousmake trial components to specification (all)free from false tool cuts, burrs or sharp edgesdimensional tolerance BS4500 or BS 1916 grade 7surface finish 63µin or 1.6µmscrew threads BS medium fitreamed & bored holes within H8angles ± 0.5 degree


Candidate: Date:

Assessor: Date:


47

Unit 7: Machining Components using Turret Lathes

Unit Summary

This unit identifies the competencies you need to carry out turning operations on a turret lathe, in accordance with approved procedures. You will be required to check that the machine is ready for the operations to be performed, and that all the required components/materials and consumables are available. You will be expected to produce a range of components that combine a number of different features, such as parallel, stepped and tapered diameters, drilled, bored and reamed holes, internal and external threads, and special forms/profiles.


Your responsibilities will require you to comply with organisational policy and procedures for the machining activities undertaken, and to report any problems with the machining activities that you cannot resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying machining procedures. You will understand the turret lathe turning process, and its application, and will know about the equipment, materials and consumables, in adequate depth to provide a sound basis for carrying out the activities to the required specification.


Setting up of the machine, its tooling and associated workholding devices, is the subject of another unit


48

Unit 7: Machining Components using Turret LathesPerformance statements:




1. machine guards are in place and correctly adjusted2. components are held securely without distortion3. cutting tools are maintained in a suitable condition● safe working practices are observed● machine settings are adjusted to maintain the required accuracy● components produced meet specification

2. Produce machined components which combine different operations and cover ten of the following: ● flat faces ● parallel diameters● stepped diameters● tapered diameters



● chamfers ● knurls/special finishes● grooves/undercuts

3. Machine components made from one of the following types of material:● ferrous● non-ferrous● non-metallic

4. Produce components within all of the following quality and accuracy standards applicable to the operation:● components to be free from false tool cuts, burrs and sharp edges● dimensional tolerance equivalent to BS 4500 or BS 1916 Grade 7● surface finish 63µin or 1.6µm ● reamed and bored holes within H8● screw threads BS medium fit● angles within +/- 0.5 degree

5. Carry out the necessary checks during production for accuracy of at least five of the following:● diameters● hole size/fit● angle/taper● surface finish

● lengths/depths● thread profile and fit● concentricity● slot/recess width


49

Unit 7: Machining Components using Turret LathesKnowledge statements:


1. The safe working practices and procedures that need to be followed while operating turret lathes2. The safety mechanisms on the machine, and the procedure for checking that they function correctly3. Operation of the machine controls in both hand and power modes, including rapid power of the turret head4. How to stop the machine in both normal and emergency situations, and the procedure for restarting after an

emergency5. The personal protective equipment that needs to be worn, and where this can be obtained6. The hazards associated with the turning operations, and how they can be minimised7. The importance of keeping the work area clean and tidy8. Where to obtain the component drawings, specifications and/or job instructions required for the components to be



points and system of tolerancing11. The main features of the turret lathe and the accessories that can be used (saddle, turret head, taper turning

attachments, profile attachments, lead screws for threading)12. The various turning operations that can be performed, and the shapes and types of tooling that can be used (solid

high speed tooling, brazed tip tooling, interchangeable tipped tooling)13. The methods that can be used to position the tooling in relationship to the workpiece14. The effects of backlash in machine slides and screws, and how this can be overcome15. How to handle and store tools safely and correctly16. Factors which affect the selection of cutting feeds and speeds, and the depth of cut that can be taken17. How the various types of material will affect the feeds and speeds that can be used18. The application of roughing and finishing cuts, and the effect on tool life, surface finish and dimensional accuracy19. The application of cutting fluids with regard to a range of different materials20. The effects of clamping the workpiece in a chuck/work holding device, and how this can cause distortion in the

finished components21. How to recognise machining faults and identify when tools need re-sharpening22. The quality control procedures used, inspection checks that need to be carried out, and the equipment that will

need to be used23. The problems that can occur with the turning activities, and how these can be overcome24. The extent of your own authority and whom you should report to when you have problems you cannot resolve


50





required)evidence typedate apply checks and practices during machining activities (all)machine guards in place and correctly adjustedcomponents held securelycutting tools in suitable condition safe working practicesmachine settings adjustedcomponents meet specificationmachined components operations (ten)flat facesparallel diametersstepped diameterstapered diametersdrilled holesbored holesreamed holes profile formsinternal threads external threadseccentric featuresparting offchamfersknurls/special finishesgrooves/undercutsmachine components material (one)ferrousnon-ferrousnon-metallicproduce components within quality and accuracy standards (all)free from false tool cuts, burrs or sharp edgesdimensional tolerance BS4500 or BS 1916 grade 7surface finish 63µin or 1.6µmscrew threads BS medium fitreamed & bored holes within H8angles ± 0.5 degreechecks for accuracy during production (five)diametershole/size fitangle/tapersurface finishlengths/depths thread profile and fitconcentricityslot/recess width


Candidate: Date:

Assessor: Date:


51

Unit 8: Setting Milling Machines for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up milling machines, such as horizontal, vertical, universal machines, planer/gantry milling machines and boring machines with milling attachments, in accordance with approved procedures. This involves selecting the appropriate workholding devices, and mounting and positioning them to the machine in the correct location for the type of operation being carried out.

You will also be expected to select the appropriate milling cutters, check them for defects, and mount and secure them to the relevant tool holding devices and machine spindle. You will also be expected to set up and align the workpiece in the correct relationship to the machine spindle, and to set the machine operating parameters to produce the workpiece to the required specification. You must produce trial cuts, and prove the machine is working satisfactorily before declaring the installation ready for production. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.

Your responsibilities will require you to comply with organisational policy and procedures for the machine setting activities undertaken, and to report any problems with the machine, cutters, equipment or setting up activities that you cannot resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting up procedures used. You will understand the milling machine used, and its application, and will know about the workholding devices, milling cutters, relevant materials, consumables and setting up procedures, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the work output is to the required specification.

You will understand the safety precautions required when working with the milling machines and their associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

This unit does not cover CNC activities, for which other units apply.


52

Unit 8: Setting Milling Machines for Production Performance statements:






2. Prepare one of the following types of milling machine for production: ● horizontal milling machine● universal milling machine● boring machines with milling attachments

● vertical milling machine● planer /gantry milling machine

3. Position, align and secure the workpiece using three of the following:● clamping direct to machine table● pneumatic or magnetic table ● machine vice (eg plain, swivel, universal)

● angle plate● vee block and clamps● fixtures

● chucks (eg. 3, 4 jaw)● indexing head/device● rotary table

4. Select and mount milling cutters to include six of the following: • face mills• slab mills/cylindrical cutters• side and face cutters

• slotting cutters• slitting saws• profile cutters

• twist drills• boring tools • end mills

• slot drills• straddle milling• gang milling

5. Set up the machine in accordance with instructions and specifications, to include all of the following:● alignment of workholding device● position of cutters in relationship to workpiece

● milling cutter revs per minute● machine guards/safety mechanisms

● linear/table feed rate ● cutting fluid flow rate ● depth of cut for roughing and finishing6. Set up the machine to produce internal and external profiles that include eight of the following:

● flat faces● square faces● parallel faces● angular faces ● steps/shoulders

● open ended slots● enclosed slots● recesses● tee slots● drilled holes

● bored holes● profile forms (vee, concave, convex, gear forms)● serrations● indexed or rotated forms● special forms

7. Machine components made from one of the following types of material: ● ferrous ● non-metallic ● non-ferrous

8. Make trial components to prove the machine is operating to required specification, to include all the following: ● components to be free from false tool cuts, burrs and sharp edges● dimensional tolerance equivalent to BS 4500 or BS 1916 Grade 7● flatness & squareness within 0.001” per inch or 0.025mm per 25mm● surface finish 63µin or 1.6µm ● angles within +/- 0.5 degree ● bored holes within H8


53

Unit 8: Setting Milling Machines for Production Knowledge statements:


1. The specific safety precautions to be taken when setting up workholding devices and milling cutters on milling machines (such as horizontal, vertical, universal, planer/gantry, boring machines with milling attachments)

2. The hazards associated with milling machines (moving parts of machinery, handling milling cutters, handling cutting fluids, airborne particles, tool breakage, insecure components) and how they can be minimised

3. Operation of the machine controls in both hand and power modes, and how to stop the machine in an emergency4. The importance of ensuring the machine is isolated from the power supply before mounting milling cutters and


and tidy6. The basic principles of operation of the various milling machines, and typical operations that they can perform7. How to handle and store milling cutters safely and correctly8. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing10. Terminology used in milling in relation to the activities undertaken11. The range of workholding methods and devices that are used on machines (direct clamping, machine vice,

pneumatic and magnetic tables, jigs and fixtures, chucks, indexing devices rotary tables, angle brackets, vee blocks and clamps)

12. The methods of mounting and setting the workpiece in/on the workholding devices, and the tools and equipment that can be used

13. The different types of milling cutters that are used, and how they are selected, prepared and mounted to the machine tool holding devices (long arbors, stub arbors, collet chucks, direct mounting to machine spindle)

14. Factors which determine speeds and feeds to be used (material, type of cutter, depth of cut, workpiece rigidity, machine condition, tolerance and finish required)

15. How the various types of material will affect the feeds and speeds that can be used16. The type of cutting fluids that are used, and precautions to be taken when handling and using them17. How to set up the various machines for the particular operations being performed18. The need to conduct trial runs, and to check that the machine is set up and running safely and correctly19. Problems that can occur with setting up the milling cutters, workholding devices and machine operating

parameters, and what to do if problems occur20. The extent of your own authority and whom you should report to when you have problems you cannot resolve


54





required)evidence typedatecarry out activities during setting up (all)machine guards in place and correctly adjustedcomponents held securelycutting tools in suitable condition safe working practicesprepare milling machine for production (one)horizontal milling machineuniversal milling machineboring machine with milling attachmentsvertical milling machineplaner/gantry milling machineposition/align/secure workpiece (three)clamping to machine tablepneumatic/magnetic tablemachine viceangle platevee block and clampsfixtureschucksindexing head/devicerotary tableselect and mount milling cutters (six)face millsslab mills/cylindrical cuttersside and face cuttersslotting cuttersslitting sawsprofile cutterstwist drillsboring toolsend millsslot drillsstraddle millinggang millingset up machine in accordance with instructions and specifications (all)workholding device alignmentposition cutters to workpiecelinear/ table feed ratecutting fluid flow ratemilling cutter revs per minguards/safety mechanismsdepth of cut for roughing/finishing






55

required)evidence typedateset up machine to produce internal/external profiles (eight)flat facessquare facesparallel faces angular facessteps/shouldersopen ended slotsenclosed slotsrecessestee slotsdrilled holesbored holesprofile formsserrationsindexed or rotated formsspecial formsmachine components (one)ferrousnon metallicnon ferrousmake trial components to specification (all)free from false tool cuts, burrs or sharp edgesdimensional tolerance BS4500 or BS 1916 grade 7flat/squareness 0.001” per inch or 0.025mm per 25mmsurface finish 63µin or 1.6µmangles ± 0.5 degreebored holes within H8


Candidate: Date:

Assessor: Date:


56

Unit 9: Machining Components using Milling Machines

Unit Summary

This unit identifies the competencies you need to carry out milling operations, in accordance with approved procedures, using machines such as horizontal, vertical, universal, planer milling machines and boring machines with milling attachments. You will be required to check that the machine is ready for the operations to be performed, and that all the required components/materials and consumables are available. You will be expected to produce a range of components that combine a number of different features, such as flat faces, parallel faces, faces that are square to each other, angular faces, steps and slots, drilled and bored holes, and special forms.


Your responsibilities will require you to comply with organisational policy and procedures for the machining activities undertaken, and to report any problems with the machining activities that you cannot resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying machining procedures. You will understand the milling process, and its application, and will know about the equipment, materials and consumables, in adequate depth to provide a sound basis for carrying out the activities to the required specification.




57

Unit 9: Machining Components using Milling MachinesPerformance statements:




• machine guards are in place and correctly adjusted• components are held securely without distortion• cutting tools are maintained in a suitable condition• safe working practices are observed• machine settings are adjusted as required to maintain the required accuracy• components produced meet specification

2. Operate one type of milling machine from the following:● horizontal milling machine● universal milling machine● boring machines with milling attachments

● vertical milling machine● planer/gantry milling machine

3. Produce machined components which combine different operations and cover eight of the following:● flat faces● square faces● parallel faces● angular faces ● steps/shoulders

● open ended slots● enclosed slots/recesses● tee slots● drilled holes● bored holes

● profile forms (vee, concave, convex, gear forms)● serrations● indexed or rotated forms● special forms

4. Machine components made from one type of material from the following: ● ferrous● non-ferrous● non-metallic

5. Produce components within all the relevant quality and accuracy standards: components to be free from false tool cuts, burrs and sharp edgesdimensional tolerance equivalent to BS 4500 or BS 1916 Grade 7flatness and squareness within 0.001” per inch or 0.025mm per 25mmsurface finish 63µin or 1.6µm

angles within +/- 0.5 degreebored holes within H8

6. Carry out the necessary checks during production for accuracy of five of the following:● dimensions● squareness● hole size/fit● surface finish

● angles● flatness● slots● recesses


58

Unit 9: Machining Components using Milling MachinesKnowledge statements:


1. The safe working practices and procedures that need to be followed while operating milling machines2. The safety mechanisms on the machine, and the procedure for checking that they function correctly3. Operation of the machine controls in both hand and power modes, and how to stop the machine in an emergency4. The personal protective equipment that needs to be worn, and where this can be obtained5. The hazards associated with the milling operations, and how they can be minimised6. The importance of keeping the work area clean and tidy7. Where to obtain the component drawings, specifications and/or job instructions required for the components to be



points and system of tolerancing10. The application of a range of milling machines (such as horizontal, vertical, universal, planer milling, and milling

attachments for boring machines)11. The various milling techniques that can be used to produce the required shapes, and the types of milling cutters

required (face mills, slab cutters, slotting cutters, side and face cutters, end mills, slot drills)12. Conventional and climb milling techniques, and when each method should be used13. The methods that can be used to position the workpiece in relation to the milling cutters14. The effects of backlash in machine slides and screws, and how this can be overcome15. How to handle and store cutting tools safely and correctly16. Factors which affect the selection of cutting feeds and speeds, and the depth of cut that can be taken (workpiece

rigidity, machine condition, type of tooling being used, material type, finish and tolerance required)17. How the various types of material will affect the feeds and speeds that can be used18. The application of roughing and finishing cuts, and the effect on tool life, surface finish and dimensional accuracy19. The application of cutting fluids with regard to a range of different materials20. The effects of clamping the workpiece, and how this can cause distortion in the finished components21. The effects of removing material, how this can cause warping/distortion of the workpiece, and how this can be

overcome22. How to recognise machining faults and identify when cutters need re-sharpening23. The quality control procedures used, inspection checks that need to be carried out, and the equipment that will

need to be used24. The problems that can occur with the milling activities, and how these can be overcome25. The extent of your own authority and whom you should report to when you have problems you cannot resolve


59





required)evidence typedate apply checks and practices during machining activities (all)machine guards in place and correctly adjustedcomponents held securelycutting tools in suitable condition safe working practicesmachine settings adjustedcomponents meet specificationoperate milling machine (one)horizontal milling machineuniversal milling machineboring machine with milling attachmentsvertical milling machineplaner/gantry milling machineproduce machined components covering (eight)flat facessquare facesparallel facesangular facessteps/shouldersopen ended slotsenclosed slots/recessestee slotsdrilled holesbored holesprofile formsserrationsindexed or rotated formsspecial formsmachine components (one)ferrousnon-ferrousnon metallicproduce components to quality/accuracy standardsfree from false tool cuts, burrs or sharp edgesdimensional tolerance BS4500 or BS 1916 grade 7surface finish 63µin or 1.6µmflat/squareness 0.001” per inch /0.025mm per25mmreamed & bored holes within H8angles ± 0.5 degree


60





required)evidence typedate checks for accuracy during production (five)dimensionssquarenesshole size/fitsurface finishanglesflatnessslotsrecesses


Candidate: Date:

Assessor: Date:


61

Unit 10: Setting Shaping, Planing or Slotting Machines for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up shaping, planing or slotting machines for production, in accordance with approved procedures. This will involve selecting the appropriate workholding devices and securing them to the machine table, and mounting and setting the workpiece in correct relationship to the cutting tools. You will be expected to select the appropriate shaping/slotting tools, check that they are in a usable condition, and mount and secure them to the relevant tool holding devices.

You will need to set the machine operating parameters to produce the workpiece to the required specification. This will involve setting the appropriate stroke length, stroke position, feeds and speeds, and determining suitable roughing and finishing cuts. You must produce trial cuts, and prove the machine is working satisfactorily before declaring the machine ready for production. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.


Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting up procedures used. You will understand the machine used, and its application, and will know about the workholding devices, shaping/slotting tools, relevant materials, consumables and setting up procedures, in adequate depth to provide a sound basis for setting up the equipment, correcting faults and ensuring the work output meets the required specification.




62

Unit 10: Setting Shaping, Planing or Slotting Machines for Production Performance statements:






2. Set up one of the following types of machine:● shaping ● planing ● slotting ● milling machine with slotting attachment

3. Select, mount and secure the workpiece using three of the following workholding devices: ● clamping direct to machine table● pneumatic or magnetic table ● machine vice (eg. plain, swivel, universal)

● angle plate● vee block and clamps● jigs/fixtures

● chucks (eg. 3 or 4 jaw)● indexing head/device● rotary table

4. Select and mount tools to include three of the following types appropriate to the machine:● flat facing ● vertical facing

● forming/profiling● recessing

● keyway slotting● spline slotting

● serrating● special slotting

5. Set up the machine in accordance with instructions and specifications, to include all of the following:● position of workpiece● position of tools in relationship to workpiece● stroke position and length mechanisms● stroke speed

● linear feed rate ● depth of cut for roughing and finishing● cutting fluid flow rate● machine guards/safety mechanisms

6. Set up machine to produce internal and external profiles that includes six of the following:● flat faces● parallel faces● faces square to each other● steps/shoulders

● angular faces● slots/grooves● key ways● splines

● flat sided holes (eg. square, hexagonal)● serrations● other specific forms


8. Make trial components to prove the machine is operating to required specification, to include all the following:● components to be free from false tool cuts, burrs and sharp edges ● dimensional tolerance equivalent to BS 4500 or BS 1916 Grade 7● flatness and squareness within 0.001” per inch or 0.025mm per 25mm● surface finish 63 µin or 1.6µm ● angles within +/- 0.5 degree


63

Unit 10: Setting Shaping, Planing or Slotting Machines for Production Knowledge statements:


1. The specific safety precautions to be taken when setting up workholding devices and accessories, workpiece and shaping/slotting tools

2. The hazards associated with shaping, planning and slotting (moving parts of machinery, handling cutting tools, handling cutting fluids, tool breakage, insecure components) and how they can be minimised

3. How to start and stop the machine in normal and emergency situations4. The importance of ensuring the machine is isolated from the power supply before mounting tools and workholding

devices5. The importance of wearing the appropriate protective clothing and equipment, and of keeping the work area clean

and tidy6. The basic principles of operation of the shaping, planning or slotting machine and its accessories, and typical

operations that they can perform7. How to handle and store shaping, planning and slotting tools safely and correctly8. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing10. Terminology used in shaping, planning or slotting in relation to the activities undertaken11. The range of work holding methods and devices that are used on shaping, planing and slotting machines (plain,

swivel and universal machine vice, three and four jaw chucks, jigs and fixtures, direct clamping to machine table, rotary and indexing devices)

12. The methods of mounting and setting the workpiece in/on the workholding devices, and the tools and equipment that can be used

13. The different types of shaping, planing and slotting tools that are used, and how they are selected, prepared and mounted to the machine tool holding devices (clapper box, slotting or planning head)

14. Factors which determine stroke speeds and feeds to be used (material, type of tooling, depth of cut, workpiece rigidity, machine condition, tolerance and finish required)

15. How the various types of materials used will affect the feeds and speeds that can be used16. The type of cutting fluids that are used, and precautions to be taken when handling and using them17. How to set up the shaping, planing or slotting machine, and its accessories, for the particular operations being

performed (setting stroke length, stroke position, angle of tool head)18. The need to conduct trial runs, and to check that the machine is set up and producing the components correctly19. Problems that can occur with setting up the workholding devices, tooling and machine operating parameters, and



64





required)evidence typedate carry out activities during setting up (all)machine guards in place and correctly adjustedcomponents held securelycutting tools in suitable condition safe working practicesset up machine (one)shapingplanningslottingmilling machine with slotting attachmentselect, mount and secure workpiece using workholding devices (three) clamping to machine tablepneumatic/magnetic tablemachine viceangle platevee block and clampsjigs/fixtureschucks (e.g 3 or 4 jaw)indexing head/devicerotary tableselect and mount tools (three)flat facingvertical facingforming/profiling recessingkeyway slottingspline slottingserratingspecial slottingset up machine in accordance with instructions and specification (all)position of workpiecetools in workpiecestroke position, length mechanismstroke speedlinear feed ratedepth of cut roughing/finishingcutting fluid flow rateguards/safety mechanisms


65





required)evidence typedate internal and external profiles (six)flat facesparallel facesfaces square to each othersteps/shouldersangular facesslots/grooveskey wayssplinesflat sided holesserrationsother specific formsmachine components (one)ferrousnon metallicnon ferrousmake trial components to required specification (all)free from false tool cuts, burrs or sharp edgesdimensional tolerance BS4500 or BS 1916 grade 7flat/squareness 0.001” per inch or 0.025mm per 25mmsurface finish 63µin or 1.6µmangles ± 0.5 degree


Candidate: Date:

Assessor: Date:


66

Unit 11: Machining Components using Shaping, Planing or Slotting Machines

Unit Summary

This unit identifies the competencies you need to carry out shaping, planing or slotting operations, in accordance with approved procedures. You will be required to check that the machine is ready for the operations to be performed, and that all the required components/materials and consumables are available. You will be expected to produce a range of components that combine a number of different features, such as flat faces, parallel faces, faces that are square to each other, angular faces, steps, slots, keyways, flat sided holes, splines and serrations.



Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying machining procedures. You will understand the shaping, planing or slotting process, and its application, and will know about the equipment, materials and consumables, in adequate depth to provide a sound basis for carrying out the activities to the required specification.




67

Unit 11: Machining Components using Shaping, Planing or Slotting MachinesPerformance statements:




• appropriate machine guards are in place and correctly adjusted• components are held securely without distortion• cutting tools are maintained in a suitable condition• safe working practices are observed• machine settings are adjusted to maintain the required accuracy• components produced meet specification

2. Operate one type of machine from the following:● shaping ● planing ● slotting ● milling machine with slotting attachment

3. Produce machined components which combine different operations and cover six of the following:● flat faces● faces that are square to each other● parallel faces● steps/shoulders

● angular faces● slots and grooves● special forms● keyways

● flat sided holes (square, hexagonal)● splines● serrations ● special forms

4. Machine components made from one type of material from the following: ● ferrous● non-ferrous● non-metallic

5. Produce components within all the relevant quality and accuracy standards:● components to be free from false tool cuts, burrs and sharp edges ● dimensional tolerance equivalent to BS 4500 or BS 1916 Grade 7● flatness and squareness within 0.001” per inch or 0.025mm per 25mm● surface finish 63 µin or 1.6µm ● angles within +/- 0.5 degree

6. Carry out the necessary checks during production for accuracy of five of the following:● dimensions● squareness● angles● flatness

● spline/serration fit● surface finish● slot/recess width● keyway position


68

Unit 11: Machining Components using Shaping, Planing or Slotting MachinesKnowledge statements:


1. The safe working practices and procedures that need to be followed while operating shaping, planing or slotting machines

2. The safety mechanisms on the machine, and the procedure for checking that they function correctly3. Operation of the machine controls in both hand and power modes, and how to stop the machine in an emergency4. The personal protective equipment that needs to be worn, and where this can be obtained5. The hazards associated with the shaping, planing or slotting operations, and how they can be minimised6. The importance of keeping the work area clean and tidy7. Where to obtain the component drawings, specifications and/or job instructions required for the components to be



points and system of tolerancing10. The various shaping, planing and slotting techniques that can be used to produce the required shapes, and the

types of tooling used (solid high speed steel, brazed tip, interchangeable tipped)11. The methods that can be used to position the workpiece in relation to the cutting tools12. The effects of backlash in machine slides and screws, and how this can be overcome13. How to handle and store cutting tools safely and correctly14. Factors which affect the selection of cutting feeds and speeds, and the depth of cut that can be taken (workpiece


overcome20. How to recognise machining faults and identify when tools need re-sharpening21. The quality control procedures used, inspection checks that need to be carried out, and the equipment that will

need to be used22. The problems that can occur with the shaping, planing or slotting activities, and how these can be overcome23. The extent of your own authority and whom you should report to when you have problems you cannot resolve


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required)evidence typedate apply checks and practices during machining activities (all)machine guards in place and correctly adjustedcomponents held securelycutting tools in suitable condition safe working practicesmachine settings adjustedcomponents meet specificationoperate machine (one)shaping planing slottingmilling machine with slotting attachmentsproduce machined components covering (six)flat facesfaces square to each otherparallel facessteps/shouldersangular facesslots and groovesspecial formskeywaysflat sided holessplinesserrationsspecial formsmachine components (one)ferrousnon-ferrousnon-metallicproduce component to quality accuracy standards (all)free from false tool cuts, burrs or sharp edgesdimensional tolerance BS4500 or BS 1916 grade 7surface finish 63µin or 1.6µmflat/squareness 0.001” per inch /0.025mm per25mmreamed & bored holes within H8checks for accuracy during production (five)dimensionssquarenessanglesflatnessspline/serration fitsurface finishslot/recess widthkeyway position


Candidate: Date:

Assessor: Date:


70

Unit 12: Setting Gear Cutting Machines for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up gear cutting machines, such as gear hobbing, gear shaping, gear shaving, gear planning and bevel gear cutting machines, in accordance with approved procedures. This involves selecting the appropriate workholding devices, and mounting and positioning them to the machine in the correct location for the type of operation being carried out. You will also be expected to select the appropriate cutters to use, and to mount and secure them to the appropriate tool holding devices.

You will be expected to check that the components and cutting tools are running true and concentric before starting the cutting operations. You will be expected to set up hob slides to the required angle, select and fit appropriate index change gears and differential gears, feed cams, determine and set parameters for axial or conventional shaving, tangential or underpass methods, diagonal or plunge methods, push or pull methods, and the appropriate feeds and speeds for the particular gears and gear cutting methods being used.

Your responsibilities will require you to comply with organisational policy and procedures for the machine setting activities undertaken, and to report any problems with the setting up activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting up procedures used. You will understand the machine used, and its application, and will know about the workholding devices, gear cutting tools, relevant materials, consumables and setting up procedures, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the work output is to the required specification.



71

Unit 12: Setting Gear Cutting Machines for Production Performance statements:






2. Set up two of the following types of machine:● gear hobbing ● gear shaping ● bevel gear cutting ● gear planing ● gear shaving

3. Select, mount and secure the workpiece using two of the following workholding devices:● arbors● mandrels

● chucks● pots

● collets● fixtures

● centres● clamps

● face plates

4. Select and mount to the appropriate tool holding device, four of the following types of gear cutting tools:● shank type hobs● protuberance hobs● skiving hobs

● inserted blade hobs● tapered hobs● single or multi-start straight hobs

● bevel gear roughing cutters● bevel gear finishing cutters ● disc type shaping/shaving cutters

● shank type shaping/shaving cutters● extended hub type shaving cutters● screwed hub type shaping/shaving cutters● special cutters

● rack type gear planing roughing cutters ● single tooth gear planing roughing cutters● rack type full fillet planing finishing cutters● single tooth full fillet planing finishing cutters

5. Prepare the machine by carrying out all the following activities applicable to the machine type:● set the slide angles ● set the speed and feed rates ● fitting differential/index change gears

● select and set climb or conventional hobbing ● set other machine operating parameters● select and fit appropriate index change gears and differential gears ● select/set shaving method (axial or conventional, tangential or underpass, diagonal or plunge)

6. Set up the machine to produce machined components that include two of the following:● external spur gear● internal spur gear

● single helical gear ● double helical gear

● chain sprockets ● serrations

● splines● straight bevel gears


8. Make trial components to prove the machine is operating to required specification, to include all the following:● components to be free from false tool cuts, burrs and sharp edges● straight splines and serrations to BS 2059 or BS1953 Class 1● spur and helical gears to BS 436 Pt 1 or BS1967 ● involute splines to BS 3550 1963 Class 1● tolerance to BS 4500 or BS1916 Grade 9 ● surface texture 63 µin or 1.6µm


72

Unit 12: Setting Gear Cutting Machines for Production Knowledge statements:


1. The specific safety precautions to be taken when setting up workholding devices and tooling on gear cutting machines.

2. The hazards associated with gear cutting machines (moving parts of machinery, handling gear cutters, handling cutting fluids, airborne particles, tool breakage, insecure components) and how they can be minimised

3. How to start and stop the machine in normal and emergency situations4. The importance of ensuring the machine is isolated from the power supply before mounting cutters and workholding

devices5. The importance of wearing the appropriate protective clothing and equipment, and of keeping the work area clean

and tidy6. How to handle and store gear cutting tools safely and correctly7. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing9. Terminology used in gear cutting in relation to the activities undertaken10. The range of workholding methods and devices that are used on gear cutting machines11. The methods of mounting and setting the workpiece in/on the workholding devices, and the tools and equipment

that can be used12. The various gear cutting operations that are used to produce the required gear forms, and the types of tooling used

(straight hobs having single and multi start, tapered hobs, shank type hobs, protuberance hobs, inserted blade hobs, skiving hobs, disc and shank type gear shaping and shaving cutters, gear planing cutters and bevel gear cutters)

13. How to check that the gear cutting tools are in a safe and serviceable condition14. The various tool holding devices that are used, and the methods of mounting and securing the gear cutting tools to

the tool holders and machine spindles15. How to set up the various machines for the particular gears being machined16. How the various types of material will affect the feeds and speeds that can be used17. The application of cutting fluids with regard to a range of different materials, and why some materials do not require

the use of cutting fluids18. The need to conduct trial runs, and to check that the machine is set up and running safely and correctly19. Problems that can occur with setting up of the tooling, workholding devices and machine operating parameters, and



73





required)evidence typedate carry out activities during setting up (all)machine guards in place and correctly adjustedcomponents held securelycutting tools in suitable condition safe working practicesset up types of machine (two)gear hobbing gear shapingbevel gear cuttinggear planinggear shavingselect, mount and secure workpiece devices (two)arborsmandrelschuckspotscolletsfixturescentresclampsface platesselect and mount to appropriate tool holding device gear cutting tools (four)shank type hobsprotuberance hobsskiving hobsshank type shaving/shapingextended hub shaving cuttersscrewed hub typespecial cuttersinserted blade hobstapered hobssingle or multi-star hobsbevel roughing cutters bevel finishing cuttersdisc type shaping/shaving cuttersrack type planing roughing cutterssingle tooth planing roughing cuttersrack type full fillet planning cuttersingle tooth full fillet planning cutter


74





required)evidence typedate applicable activities to prepare the machine type (all)set the slide anglesclimb/conventional hobsindex change gearsselect/set shaving methodspeed and feed ratesfitting differential/indexoperating parametersset up machine to produce machined components (two)external spur gearinternal spur gearsingle helical geardouble helical gearchain sprocketsserrationssplinesstraight bevel gearsmachine components (one)ferrousnon-metallicnon-ferrousmake trial components to specification (all)free from tool cuts, burrs, sharp edgessplines/serrations to BS 2059 BS1953 Class 1spur/helical gears to BS436 Pt1 or BS1967tolerance BS4500/ BS1916 Grade 9involute splines to BS 3550 1963 Class 1surface texture 63µin or 1.6µm


Candidate: Date:

Assessor: Date:


75

Unit 13: Machining Components using Gear Cutting Machines

Unit Summary

This unit identifies the competencies you need to carry out gear cutting operations, in accordance with approved procedures, using machines such as gear hobbing, gear shaping, gear shaving, gear planing, bevel gear cutting. You will be required to check that the machine is ready for the operations to be performed, and that all the required components/materials and consumables are available. You will be expected to produce a range of gears, such as external spur gears, internal spur gears, helical and double helical gears, bevel gears, chain sprockets, external splines and serrations.



Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying machining procedures. You will understand the gear cutting process undertaken, and its application, and will know about the equipment, materials and consumables, in adequate depth to provide a sound basis for carrying out the activities to the required specification.




76

Unit 13: Machining Components using Gear Cutting MachinesPerformance statements:




• appropriate machine guards are in place and correctly adjusted• components are held securely without distortion• cutting tools are maintained in a suitable condition• safe working practices are observed• machine settings are adjusted to maintain the required accuracy• components produced meet specification

2. Operate two types of gear cutting machine from the following:● gear hobbing● gear shaping

● bevel gear cutting● gear planing

● gear shaving

3. Produce two of the following types of machined components:● external spur gear● internal spur gear


● chain sprockets ● serrations

● splines● straight bevel gears

4. Machine gears made from one of the following types of material: ● ferrous● non-ferrous● non-metallic

5. Produce components within all of the following quality and accuracy standards applicable to the operation:● components to be free from false tool cuts, burrs and sharp edges● straight splines and serrations to BS 2059 or BS1953 Class 1● spur and helical gears to BS 436 Pt 1 or BS1967● involute splines to BS 3550 1963 Class 1● tolerance to BS 4500 or BS1916 Grade 9● surface texture 63 µin or 1.6µm

6. Carry out the necessary checks during production for accuracy of five of the following:● gear blanks● lead and helix angle● gear tooth thickness● involute form

● composite error rolling test● surface texture


77

Unit 13: Machining Components using Gear Cutting MachinesKnowledge statements:


1. The safe working practices and procedures that need to be followed while operating gear hobbing, shaping, shaving and planing machines

2. The safety mechanisms on the machine, and the procedure for checking that they function correctly3. Operation of the machine controls in both hand and power modes, and how to stop the machine in an emergency4. The personal protective equipment that needs to be worn, and where this can be obtained5. The hazards associated with the gear cutting operations, and how they can be minimised6. The importance of keeping the work area clean and tidy7. Where to obtain the component drawings, specifications and/or job instructions required for the components to be


conventions to appropriate BS or ISO standards in relation to work undertaken 9. How to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference

points and system of tolerancing10. Terminology used in gear cutting in relation to the activities undertaken11. The various gear cutting operations that are used to produce the required gear forms, and the types of tooling used

(straight hobs having single and multi start, tapered hobs, shank type hobs, protuberance hobs, inserted blade hobs, skiving hobs, disc and shank type gear shaping and shaving cutters, gear planing cutters and bevel gear cutters)

12. The methods that can be used to position the workpiece in relation to the cutting tools13. The importance of checking blank and cutter concentricity, and the tools and equipment that are used14. The effects of backlash in machine slides and screws, and how this can be overcome15. How to handle and store cutting tools safely and correctly16. Factors which affect the selection of cutting feeds and speeds, and the depth of cut that can be taken (workpiece

rigidity, machine condition, type of tooling being used, material type, finish and tolerance required)17. How the various types of material will affect the feeds and speeds that can be used18. The application of roughing and finishing cuts, and the effect on tool life, surface finish and dimensional accuracy19. The application of cutting fluids with regard to a range of different materials20. The effects of clamping the workpiece, and how this can cause distortion in the finished components21. How to recognise machining faults and identify when tools need re-sharpening22. The quality control procedures used, inspection checks that need to be carried out, and the equipment that will need

to be used23. The problems that can occur with the gear cutting activities, and how these can be overcome24. The extent of your own authority and whom you should report to when you have problems you cannot resolve


78





required)evidence typedate apply checks and practices during machining activities (all)machine guards in place and correctly adjustedcomponents held securelycutting tools in suitable condition safe working practicesmachine settings adjustedcomponents meet specificationoperate gear cutting machines (two)gear hobbinggear shapingbevel gear cuttinggear planninggear shavingproduce machined components (two)external spur gear internal spur gearsingle helical geardouble helical gearchain sprocketsserrationssplinesstraight bevel gearsmachine gears (one)ferrousnon-ferrousnon-metallicproduce components within quality and accuracy standards (all)free from tool cuts, burrs, sharp edgesstraight splines and serrations to BS2059 / BS1953 Class 1spur and helical gears to BS436 Pt1/BS1967involute splines to BS3550 1963 Class 1tolerance to BS4500/BS1916 Grade 9surface texture 63µin or 1.6µm


79





required)evidence typedate checks for accuracy during production (five)gear blankslead and helix anglegear tooth thicknessinvolute formcomposite error rolling testsurface texture


Candidate: Date:

Assessor: Date:


80

Unit 14: Setting Gear Grinding Machines for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up gear grinding machines, which cover gear grinding using formed wheels and gear grinding using generation methods, and will include the grinding of spur gears, helical, bevel gears and splines, in accordance with approved procedures. This involves selecting the appropriate workholding devices, and mounting and positioning them to the machine in the correct location for the type of operation being carried out. You will also be expected to select the appropriate grinding wheels to use, check them for defects, balance them when appropriate, and mount and secure them to the machine spindle. You will also be expected to mount the gears to be ground, and to check that they are running true and concentric before starting the grinding operations.

You will be expected to prepare the grinding wheels for operation, by mounting the correct templates and dressing the wheels to the correct form, or mounting the correct crushing rolls and forming the wheels to the correct profiles. You must set up the appropriate mechanisms and controls for indexing, selecting and fitting appropriate change gears or roll gears for generation, workspeed, setting the angle of the wheelhead and workhead, feeds and speeds, as applicable for the particular gears and gear grinding methods being used. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.

Your responsibilities will require you to comply with organisational policy and procedures for the machine setting activities undertaken, and to report any problems with the grinding machines, equipment or setting up activities that you cannot resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting up procedures used. You will understand the gear grinding machines used, and their application, and will know about the workholding devices, grinding wheels, wheel forming and setting up procedures, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the work produced is to the required specification.


This unit does not cover CNC gear grinding, for which other units apply.


81

Unit 14: Setting Gear Grinding Machines for Production Performance statements:






2. Prepare one of the following gear grinding machines in readiness for production:● gear grinding using formed wheels ● gear grinding using generation

3. Position and secure workpieces using two of the following work holding arrangements:● mandrels ● arbors

● pots ● centres

● chucks● collets

● clamps● face plates

● jigs/fixtures

4. Select and mount grinding wheels to include all of the following:● selecting gear grinding wheels for specific materials and gear pitch (grain size, grade, structure, bond)● mounting wheels (paper washers, flanges, locking pressure)● testing wheels for cracks ● balancing wheels, where appropriate

5. Set up gear grinding machines, to include four of the following as appropriate to machine type:● setting up diamond tools for use in pantograph and wheel dressing units● selecting and mounting correct templates for the specific gear tooth form● selecting and mounting correct crushing rolls for the specific gear tooth form● dressing and ‘trueing up’ single and multi-ribbed grinding wheels● setting index plates or change gears for number of teeth to be ground● selecting and fitting of pitch block and tapes for diameter of pitch circle to be ground ● selecting and fitting workspeed gears● setting wheelhead and workhead angle for helical gears

6. Set up a machine to grind two of the following gear forms applicable to the machine type:● external spur gear● internal spur gear


● bevel gears● straight splines

● involute splines ● tip and root relief

7. Grind gears made from one of the following types of material:● ferrous ● non-ferrous ● non-metallic

8. Make trial components to prove the machine is operating to required specification to include all the following: ● dimensional tolerance equivalent to BS 4500 Grade 5 or BS1916 ● surface texture 8 µin or 0.2µm ● components to be free from false grinding cuts, burrs and sharp edges


82

Unit 14: Setting Gear Grinding Machines for Production Knowledge statements:


1. The specific safety precautions to be taken when setting up workholding devices and grinding wheels on gear grinding machines

2. Your duties and responsibilities under The Abrasive Wheels Regulations, with particular reference to the mounting of abrasive wheels

3. The hazards associated with gear grinding (moving parts of machinery, sparks/airborne particles, bursting grinding wheels) and how they can be minimised

4. How to start and stop the machine in normal and emergency situations5. The importance of ensuring the machine is isolated from the power supply before mounting grinding wheels and


and tidy7. How to handle and store gear grinding wheels safely and correctly8. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing10. Terminology used in gear grinding in relation to the activities undertaken11. The range of workholding methods and devices that are used on gear grinding machines12. The methods of mounting and setting the workpiece in/on the workholding devices, and the tools and equipment

that can be used13. The various gear grinding operations that are used to produce the required gear forms, and the types of wheels that

are used14. How to check that the grinding wheels are in a safe and serviceable condition (free from damage, cracks, correctly

balanced)15. The methods of mounting and securing the grinding wheels to the machine spindles16. Methods of forming the wheels to the required gear profile (use of pantograph and wheel dressing units, use of

crushing rolls)17. The need for ‘trueing up’ and dressing of wheels to prevent glazing and burning of workpiece18. How to set up the various machines for the particular gears being ground19. How the various types of material will affect the feeds and speeds that can be used20. The application of cutting fluids with regard to a range of different materials21. The need to conduct trial runs, and to check that the machine is set up and running safely and correctly22. Problems that can occur with setting up of the grinding wheels, workholding devices and machine operating

parameters, and what to do if problems occur23. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


83





required)evidence typedate carry out activities during setting up (all)machine guards placedhold components securelysafe working practicestools in suitable conditiongear grinding machine in readiness for production (one)using formed wheelsusing generationposition and secure workpieces using holding arrangements (two)mandrelsarborspotscentreschuckscolletsclampsface plates jigs/fixturesselect and mount grinding wheels (all)gear grinding wheelsmounting wheelstesting wheels for cracksbalancing wheelsset up gear grinding machines (four)set up diamond toolsmounting correct templatescorrect crushing rollsmulti ribbed grinding wheelssetting index platesfitting of pitch block/tapesfitting workspeed gearssetting wheelhead/ workhead anglesetting up machine to grind following gear forms (two)external spur gearinternal spur gearsingle helical geardouble helical gearbevel gearsstraight splinesinvolute splinestip and root relief


84





required)evidence typedate grind gears made from following material (one)ferrousnon ferrousnon metallicmachine operated to required specification (all)BS4500 grade 5 BS1916texture 8µin or 0.2µmfalse grinding cuts, burrs, sharp edges


Candidate: Date:

Assessor: Date:


85

Unit 15: Machining Components using Gear Grinding Machines

Unit Summary

This unit identifies the competencies you need to carry out gear grinding operations, in accordance with approved procedures. You will be required to check that the machine is ready for the operations to be performed, and that all the required components, consumables and gear measuring equipment is available. You will be expected to grind a range of gears, such as spur gears, helical and double helical gears, bevel gears, and splines.

You must operate the machine in line with safe working practices and approved procedures, and continuously monitor the machining operations, making any necessary adjustments to settings in order to ensure that the work output is to the required quality and accuracy. Meeting production targets will be an important issue, and your production records must show consistent and satisfactory performance.

Your responsibilities will require you to comply with organisational policy and procedures for the grinding activities undertaken, and to report any problems with the grinding activities that you cannot resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying gear grinding procedures. You will understand the gear grinding process undertaken, and its application, and will know about the equipment, materials and consumables, in adequate depth to provide a sound basis for carrying out the activities to the required specification.




86

Unit 15: Machining Components using Gear Grinding MachinesPerformance statements:




• appropriate machine guards are in place and correctly adjusted• components are held securely without distortion• grinding wheels are maintained, correctly formed, and in a usable condition• safe working practices are observed• machine settings are adjusted to maintain the required accuracy• components produced meet specification

2. Operate one of the following types of gear grinding machine:● gear grinding using formed wheels● gear grinding by generation

3. Finish grind two of the following types of gears applicable to the machine type:● external spur gear● internal spur gear● single helical gear ● double helical gear

● bevel gears● straight splines● involute splines ● tip and root relief

4. Grind gears made from one of the following types of material:● ferrous● non-ferrous● non-metallic

5. Produce components within all the relevant quality and accuracy standards:● dimensional tolerance equivalent to BS 4500 Grade 5 or BS1916 ● surface texture 8 µin or 0.2µm ● components to be free from false grinding cuts, burrs and sharp edges

6. Carry out the necessary checks during production for accuracy of four of the following:● gear tooth profile● lead and pitch● gear tooth thickness● involute form● concentricity● surface texture


87

Unit 15: Machining Components using Gear Grinding MachinesKnowledge statements:


1. The safe working practices and procedures that need to be followed while operating gear grinding machines2. Your duties and responsibilities under The Abrasive Wheels Regulations, with particular reference to the mounting

of abrasive wheels3. The safety mechanisms on the machine, and the procedure for checking that they function correctly4. Operation of the machine controls in both hand and power modes, and how to stop the machine in an emergency5. The personal protective equipment that needs to be worn, and where this can be obtained6. The hazards associated with the gear grinding operations, and how they can be minimised7. The importance of keeping the work area clean and tidy8. Where to obtain the component drawings, specifications and/or job instructions required for the components to be



points and system of tolerancing11. Terminology used in gear grinding in relation to the activities undertaken12. The various gear grinding operations that are used to produce the required gear forms, and the types of grinding

wheels used13. How to dress and reshape single and multi-ribbed grinding wheels, and the equipment to be used 14. The methods that can be used to position the gear in relation to the grinding wheel15. The importance of checking the gear concentricity before grinding, and tools and equipment that are used16. The effects of backlash in machine slides and screws, and how this can be overcome17. How to handle and store grinding wheels safely and correctly18. Factors which affect the selection of grinding wheel feeds and speeds, and the depth of cut that can be taken

(wheel size, material type, finish and tolerance required)19. The application of roughing and finishing cuts, and the effect on wheel life, surface finish and dimensional accuracy20. The reason for using cutting fluids, and the type of fluid used21. The effects of clamping the workpiece, and how this can cause distortion in the finished components22. How to recognise grinding faults and identify when grinding wheels need re-dressing/forming23. The quality control procedures used, inspection checks that need to be carried out, and the equipment that will

need to be used24. The problems that can occur with the gear grinding activities, and how these can be overcome25. The extent of your own authority, and whom you should report to when you have problems you cannot resolve


88





required)evidence typedate apply checks and practices during machining activities (all)machine guards in place and correctly adjustedcomponents held securelycutting tools in suitable condition safe working practicesmachine settings adjustedcomponents meet specificationoperate types of gear grinding machine (one)grinding using formed wheelsgrinding by generationgrind finish types of gears applicable to machine (two)external spur gearinternal spur gearsingle helical geardouble helical gearbevel gearsstraight splinesinvolute splinestip and root reliefgrind gears from (one)ferrousnon-ferrousnon-metallicproduce components within quality and accuracy standards (all)tolerance to BS4500 Grade 5 BS1916surface texture 8µin or 0.2µmno grinding cuts, burrs, sharp edgeschecks during production accuracy (four)gear tooth profilelead and pitchgear tooth thicknessinvolute formconcentricitysurface texture


Candidate: Date:

Assessor: Date:


89

Unit 16: Setting Horizontal Boring Machines for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up horizontal boring machines, and horizontal boring attachments, in accordance with approved procedures. This involves selecting the appropriate workholding devices, and mounting and positioning them to the machine in the correct location for the type of operation being carried out. You will also be expected to select the appropriate horizontal boring tools and cutters, check them for defects, and mount and secure them to the relevant tool holding devices and machine spindle.

You will be expected to set up and align the workpiece in the correct relationship to the machine spindle, and to set the machine operating parameters to produce the workpiece to the required specification. You must produce trial cuts, and prove the machine is working satisfactorily before declaring the installation ready for production. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.

Your responsibilities will require you to comply with organisational policy and procedures for the machine setting activities undertaken, and to report any problems with the machine, cutters, tools, equipment or setting up activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting up procedures used. You will understand the horizontal boring machine used, and its application, and will know about the workholding devices, cutters, tools, relevant materials and consumables, and setting up procedures, in adequate depth to provide a sound basis for carrying out the activities to the required specification.




90

Unit 16: Setting Horizontal Boring Machines for Production Performance statements:






2. Prepare the machine and its equipment in readiness for production, to include all of the following:● lifting equipment● slings

● boring heads● tool/cutter holding devices

● workholding devices

3. Position, align and secure the workpiece using three of the following work holding arrangements:● clamping direct to machine table● machine vice (eg. plain, swivel, universal)● three jaw chucks, hard jaws● pneumatic or magnetic table

● indexing/rotating device● vee block and clamps● three jaw chucks, soft jaws● other workholding devices

● four jaw chucks● fixtures● angle plate

4. Select and mount horizontal boring tools/cutters to include seven of the following: ● boring ● turning

• facing• recessing

• twist drills• chamfering or radii

• reamers• taps

• forming• milling cutters

5. Set up the machine in accordance with instructions and specifications to include all of the following:● alignment of workholding device/workpiece● position of cutters/tools in relationship to workpiece● position of cutters/tools in relationship to datums● feed rate

● cutter/tool revolutions per minute● depth of cut for roughing and finishing● cutting fluid flow rate● machine guards/safety mechanisms

6. Set up the machine to produce internal and external profiles that include ten of the following: ● bored holes through workpiece ● bored holes to a depth● tapered bores● drilled holes to depth● drilled holes through workpiece● reamed holes

● threaded holes● external diameters● grooves/recesses● chamfers/radii● flat faces● square faces

● parallel faces● angular faces ● slots● indexed or rotated forms

7. Machine components made from one of the following types of material: ● ferrous ● non-ferrous ● non-metallic

8. Make trial components to prove the machine is operating to required specification, to include all the following:● components to be free from false tool cuts, burrs and sharp edges● flatness and squareness within 0.001” per inch or 0.025mm per 25mm● dimensional tolerance equivalent to BS 4500 Grade 7 or BS 1916 ● surface finish 63 µin or 1.6µm ● angles within +/- 0.5 degree ● bored holes within H8


91

Unit 16: Setting Horizontal Boring Machines for Production Knowledge statements


1. The specific safety precautions to be taken when setting up workholding devices, tools and cutters on horizontal boring machines

2. The hazards associated with horizontal boring machines (moving parts of machinery, handling tools and cutters, lifting and moving workpieces, handling cutting fluids, airborne particles, tool breakage, insecure components) and how they can be minimised

3. How to start and stop the machine in normal and emergency situations4. The importance of ensuring the machine is isolated from the power supply before mounting tools, cutters,

workpieces and work holding devices5. The importance of wearing the appropriate protective clothing and equipment, and of keeping the work area clean

and tidy6. The basic principles of operation of the horizontal boring machine, and typical operations that it can perform7. How to handle and store tools and cutters safely and correctly8. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing10. Terminology used in horizontal boring in relation to the activities undertaken11. The range of workholding methods and devices that are used on machines (direct clamping, machine vices, jigs and

fixtures, angle brackets, vee blocks and clamps)12. The methods of mounting and setting the workpiece in/on the workholding devices, and the tools and equipment

that can be used13. The different types of horizontal boring tools and cutters that are used, and how they are selected, prepared and

mounted to the machine tool holding devices (tool posts, micro boring bars, arbors, collet chucks, direct mounting to machine spindle)

14. Factors which determine speeds and feeds to be used (material, type of cutter/tool, depth of cut, workpiece rigidity, machine condition, tolerance and finish required)

15. How the various types of material will affect the feeds and speeds that can be used16. The type of cutting fluids that are used, and precautions to be taken when handling and using them17. How to set up the machine for the particular operations being performed18. The need to conduct trial runs, and check that the machine is set up and running safely and correctly19. Problems that can occur with setting up the horizontal boring machine, tools and cutters, work holding devices and

machine operating parameters, and what to do if problems occur20. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


92





required)evidence typedate carry out activities during setting up (all))machine guards in place and correctly adjustedcomponents held securelycutting tools in suitable condition safe working practicesprepare machine and equipment for production (all)lifting equipmentslingsboring headstool/cutter devicesworkholding devicesposition, align and secure the workpiece (three)clamping to machine tablesmachine vicethree jaw chucks, hard jawspneumatic/magnetic tableindexing/rotating devicevee block /clampsthree jaw chucks, soft jawsother workholding devicesfour jaw chucksfixturesangle plateselect and mount horizontal boring tools/cutters (seven)boringturningfacingrecessingtwist drillschamfering or radiireamerstapsformingmilling cuttersset up machine in accordance with instructions and specifications (all)alignment workholding devicecutters/tools to workpiececutters/tools to daturnsfeed rate cutter/tool rev/mindepth of cut for roughing /finishingcutting fluid flow ratemachine guards/safety mechanisms


93





required)evidence typedate set up machine to produce internal and external profiles (ten)bored holes through workpiecebored holes to a depthtapered boresdrilled holes to a depthdrilled holes through workpiecereamed holesthreaded holesexternal diametersgrooves/recesseschamfers/radiiflat facessquare facesparallel facesangular facesslotsindexed or rotated formsmachine components (one)ferrousnon-ferrousnon-metallicmake trial components to specification (all)free from tool cuts, burrs, sharp edgesflat/squareness 0.001” per inch or 0.025mm per 25mmdimensional tolerance BS4500 or BS 1916 grade 7surface finish 63µin or 1.6µmangles ± 0.5 degree


Candidate: Date:

Assessor: Date:


94

Unit No 17: Machining Components using Horizontal Boring Machines

Unit Summary

This unit identifies the competencies you need to carry out horizontal boring operations, in accordance with approved procedures, using horizontal boring machines and associated boring attachments. You will be required to check that the machine is ready for the operations to be performed, and that all the required components or materials and consumables are available. You will be expected to produce a range of components that combine a number of different features, such as drilled and reamed holes, parallel and tapered bored holes, counterbores, threads and special forms, external diameters, flat, parallel and square faces, steps and slots, radii and chamfers.



Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying machining procedures. You will understand the horizontal boring process, and its application, and will know about the equipment, materials and consumables, in adequate depth to provide a sound basis for carrying out the activities to the required specification.


This unit does not cover NC/CNC applications, for which other units apply.



95

Unit No 17: Machining Components using Horizontal Boring MachinesPerformance statements:




• machine guards are in place and correctly adjusted• components are held securely without distortion• cutting tools are maintained in a suitable condition• safe working practices are observed• machine settings are adjusted to maintain the required accuracy• components produced meet specification

2. Produce machined components which combine different operations and cover ten of the following:● bored holes through workpiece ● bored holes to a depth● tapered bores● drilled holes to depth● drilled holes through workpiece● reamed holes

● threaded holes● external diameters● grooves/recesses● chamfers/radii● flat faces● square faces

● parallel faces● angular faces ● slots● indexed or rotated forms

3. Machine components made from one type of material from the following: ● ferrous ● non-ferrous● non-metallic

4. . Produce components within all the relevant quality and accuracy standards: ● components to be free from false tool cuts, burrs and sharp edges● flatness and squareness within 0.001” per inch or 0.025mm per 25mm● dimensional tolerance equivalent to BS 4500 Grade 7 or BS 1916 ● surface finish 63 µin or 1.6µm ● angles within +/- 0.5 degree● bored holes within H8

5. Carry out the necessary checks during production for accuracy of six of the following: ● external diameters● internal diameters● lengths/depths● reamed hole size/fit● tapers/angles

● thread fit● slot/recess width ● surface finish● flatness of faces ● squareness of faces


96

Unit No 17: Machining Components using Horizontal Boring MachinesKnowledge statements:


1. The safe working practices and procedures that need to be followed while operating horizontal boring machines2. The safety mechanisms on the machine, and the procedure for checking that they function correctly3. Operation of the machine controls in both hand and power modes, and how to stop the machine in an emergency4. The personal protective equipment that needs to be worn, and where this can be obtained5. The hazards associated with the horizontal boring operations, and how they can be minimised6. The importance of keeping the work area clean and tidy7. Where to obtain the component drawings, specifications and/or job instructions required for the components to be



points and system of tolerancing10. The application of a range of horizontal boring machines and horizontal boring attachments11. The various horizontal boring techniques that can be used to produce the required shapes, and the types of

horizontal boring cutters and tools required (turning tools, single and multiple tool boring bars, milling cutters, drills, taps, profile tools)

12. The methods that can be used to position the workpiece in relation to the horizontal boring cutters and tools13. The effects of backlash in machine slides and screws, and how this can be overcome14. How to handle and store cutting tools safely and correctly15. Factors which affect the selection of cutting feeds and speeds, and the depth of cut that can be taken (workpiece

rigidity, machine condition, type of tooling being used, material type, finish and tolerance required)16. How the various types of materials will affect the feeds and speeds that can be used17. The application of roughing and finishing cuts, and the effect on tool life, surface finish and dimensional accuracy18. The application of cutting fluids with regard to a range of different materials19. The effects of clamping the workpiece, and how this can cause distortion in the finished components20. The effects of removing material and, how this can cause warping/distortion of the workpiece, and how this can be

overcome21. How to recognise machining faults and identify when tools/cutters need re-sharpening22. The quality control procedures used, inspection checks that need to be carried out, and the equipment that will

need to be used23. The problems that can occur with the horizontal boring activities, and how these can be overcome24. The extent of your own authority and whom you should report to when you have problems you cannot resolve


97





required)evidence typedate apply checks and practices during machining activities (all)machine guards in place and correctly adjustedcomponents held securelycutting tools in suitable condition safe working practicesmachine settings adjustedcomponents meet specificationproduce machined components covering (ten)bored holes through workpiecebored holes to a depthtapered boresdrilled holes to depthdrilled holes through workpiecereamed holesthreaded holesexternal diametersgrooves/recesseschamfers/radiiflat facessquare facesparallel facesangular facesslotsindexed or rotated formsmachine components (one)ferrousnon-ferrousnon-metallicproduce components within quality and accuracy standards (all)free from false tool cuts, burrs or sharp edgesdimensional tolerance BS4500 or BS 1916 grade 7surface finish 63µin or 1.6µmflat/squareness 0.001” per inch /0.025mm per25mmreamed & bored holes within H8angles ± 0.5 degree


98





required)evidence typedate carry out accuracy checks during production (six)external diametersinternal diameterslengths/depthsreamed hole size/fittapers/anglesthread fitslot/recess widthsurface finishflatness of facessquareness of faces


Candidate: Date:

Assessor: Date:


99

Unit No 18: Setting Vertical Boring Machines for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up vertical boring machines and vertical boring attachments, in accordance with approved procedures. This involves selecting the appropriate workholding devices, and mounting and positioning them to the machine in the correct location for the type of operation being carried out. You will also be expected to select the appropriate boring tools and cutters, check them for defects, and mount and secure them to the relevant tool holding devices and machine spindle.

You will also be expected to set up and align the workpiece in the correct relationship to the machine spindle, and to set the machine operating parameters to produce the workpiece to the required specification. You must produce trial cuts, and prove the machine is working satisfactorily before declaring the installation ready for production. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.

Your responsibilities will require you to comply with organisational policy and procedures for the machine setting activities undertaken, and to report any problems with the machine, cutters, tools, equipment or setting up activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting up procedures used. You will understand the vertical boring machine used, and its application, and will know about the workholding devices, cutters, tools, grinding wheels, tool holding attachments, relevant materials, consumables and setting up procedures, in adequate depth to provide a sound basis for carrying out the activities to the required specification.


This unit does not cover NC/CNC activities, for which other units apply.


100

Unit No 18: Setting Vertical Boring Machines for Production Performance statements:



You must:1. Carry out all the following activities during setting up:● ensure correctly adjusted machine guards are in place● check cutting tools are in a suitable condition


2. Prepare the machine and equipment in readiness for production, to include all the following: ● lifting equipment● side heads

● turret heads/slides● tool/cutter holding devices

● workholding devices● multi-tooling

● tool post

3. Position, align and secure the workpiece using three of the following:● clamping direct to machine table● machine vice(eg. plain, swivel, universal)● three jaw chucks (hard jaws)

pneumatic or magnetic table

● indexing/rotating device● vee block and clamps● three jaw chucks (soft jaws)● other workholding devices


4. Select and mount vertical boring tools and cutters, to include eight of the following: ● boring ● turning

• facing• recessing

• twist drills• chamfering/radii

• reamers• taps

• forming• threading

• milling cutters• grinding wheel

5. Set up the machine in accordance with instructions and specifications, to include all of the following:● position of cutters/tools/grinding wheels in relationship to workpiece ● cutting fluid flow rate

● cutter/tools/grinding wheel revs per minute● alignment of workholding device/workpiece

● machine guards/safety mechanisms● depth of cut for roughing/finishing

● feed rate

6. Set up the machine to produce internal and external profiles that include ten of the following:● external diameters● internal diameters● indexed or rotated forms● recesses and grooves

● external tapers● taper bores● drilled holes● reamed holes

● milled faces● milled slots● ground diameters● steps

● ground faces● threads● radii/chamfers● turned faces

7. Machine components made from one type of material from the following:● ferrous ● non-ferrous ● non-metallic

8. Make trial components to prove the machine is operating to required specification, to include all the following:● components to be free from false tool cuts, burrs and sharp edges● dimensional tolerance equivalent to BS 4500 Grade 7 or BS 1916 ● flatness and squareness within 0.001” per inch or 0.025mm per 25mm● surface finish 63 µin or 1.6µm ● angles within +/- 0.5 degree ● bored holes within H8


101

Unit No 18: Setting Vertical Boring Machines for Production Knowledge statements


1. The specific safety precautions to be taken when setting up workholding devices, tools and cutters on vertical boring machines

2. The hazards associated with vertical boring machines (moving parts of machinery, handling tools and cutters, lifting and moving workpieces, handling cutting fluids, airborne particles, tool breakage, insecure components) and how they can be minimised

3. How to start and stop the machine in normal and emergency situations4. The importance of ensuring the machine is isolated from the power supply before mounting tools, cutters,

workpieces and work holding devices5. The importance of wearing the appropriate protective clothing and equipment, and of keeping the work area clean

and tidy6. The basic principles of operation of the vertical boring machine, and typical operations that they can perform7. How to handle and store tools and cutters safely and correctly (turning tools, milling cutters, grinding wheels)8. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing10. Terminology used in vertical boring in relation to the activities undertaken11. The range of workholding methods and devices that are used on vertical boring machines (three and four jaw chucks,

hard and soft jaws, direct clamping to machine table, jigs and fixtures, machine vice, angle plates)12. The methods of mounting and setting the workpiece in/on the workholding devices, and the tools and equipment

that can be used13. The different types of vertical boring tools, cutters and grinding wheels that are used, and how they are selected,

prepared and mounted to the machine tool holding devices (boring bars, collet chucks, stub arbors, tool posts, direct mounting to machine spindle)

14. The types of vertical boring attachments that are used, and their application15. Factors which determine speeds and feeds to be used (material, type of cutter/tool/grinding wheel, depth of cut,

workpiece rigidity, machine condition, tolerance and finish required)16. How the various types of material will affect the feeds and speeds that can be used17. The type of cutting fluids that are used, and precautions to be taken when handling and using them18. How to set up the machine for the particular operations being performed19. The need to conduct trial runs, and to check that the machine is set up and running safely and correctly20. Problems that can occur with setting up the vertical boring tools and cutters, work holding devices and machine

operating parameters, and what to do if problems occur21. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


102





required)evidence typedate carry out activities during setting up (all)machine guards in place and correctly adjustedcomponents held securelycutting tools in suitable condition safe working practicesprepare machine equipment in readiness for production (all)lifting equipmentside headsturret heads/slidestool/cutter holding devicesworkholding devicesmulti-toolingtool postposition, align and secure the workpiece (three)clamping to machine tablemachine vicethree jaw chucks (hard)pneumatic or magnetic tableindexing/rotating devicevee block clampsthree jaw chucks (soft)other workholding devicesfour jaw chucksfixturesangle plateselect and mount vertical boring tools/cutters (eight)boringturningfacingrecessingtwist drillschamfering/radiireamerstapsformingthreadingmilling cuttersgrinding wheel


103

Unit No 18: Setting Vertical Boring Machines for Production





required)set up machine in accordance with instructions and specifications (all)position cutters/tools grinding wheel grinding wheel rev/minuteworkholding device/workpiecemachine guards/safety mechanismdepth of cut roughing/finishingcutting fluid flow ratefeed rateset up machine to produce internal/external profiles including (ten)external diameters internal diametersindexed or rotated formsrecesses and groovesexternal taperstaper boresdrilled holesreamed holesmilled facesmilled slotsground diametersstepsground facesthreadsradii/chamfersturned facesmachine components from (one)ferrousnon-ferrousnon-metallicmake trial components to required specification (all)free from tool cuts, burrs, sharp edgestolerance to BS4500 Grade 7/ BS1916flat/squareness 0.001” per inch or 0.025mm per 25mmsurface finish 63µin or1.6µmangles within +/- 0.5 degreebored hole within H8


Candidate: Date:

Assessor: Date:


104

Unit No 19: Machining Components using Vertical Boring Machines

Unit Summary

This unit identifies the competencies you need to carry out vertical boring operations, in accordance with approved procedures, using vertical boring machines and associated vertical boring attachments. You will be required to check that the machine is ready for the operations to be performed, and that all the required components or materials and consumables are available. You will be expected to produce a range of components that combine a number of different features, such as parallel diameters, parallel bores, external tapers, taper bores, steps, faces, radii, threads, ground diameters, milled faces and milled slots or profiles.



Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying machining procedures. You will understand the vertical boring process, and its application, and will know about the equipment, materials and consumables, in adequate depth to provide a sound basis for carrying out the activities to the required specification.


This unit does not cover NC/CNC applications, for which other units apply.



105

Unit No 19: Machining Components using Vertical Boring MachinesPerformance statements:




● machine guards are in place and correctly adjusted● components are held securely without distortion● cutting tools are maintained in a suitable condition● safe working practices are observed● machine settings are adjusted to maintain the required accuracy● components produced meet specification

2. Produce machined components which combine different operations and cover ten of the following:● external diameters● internal diameters● indexed or rotated forms● recesses and grooves

● external tapers● taper bores● drilled holes● reamed holes

● milled faces● milled slots● ground diameters● steps

● ground faces● threads● radii/chamfers● turned faces

3. Machine components made from one type of material from the following: ● ferrous ● non-ferrous● non-metallic

4. Produce components within all the relevant quality and accuracy standards:● components to be free from false tool cuts, burrs and sharp edges● dimensional tolerance equivalent to BS 4500 Grade 7 or BS 1916 ● flatness and squareness within 0.001” per inch or 0.025mm per 25mm● surface finish 63 µin or 1.6µm ● angles within +/- 0.5 degree● bored holes within H8

5. Carry out the necessary checks during production for accuracy of five of the following:● external diameters● internal diameters● lengths/depths● reamed hole size/fit● tapers/angles



106

Unit No 19: Machining Components using Vertical Boring MachinesKnowledge statements:


1. The safe working practices and procedures that need to be followed while operating vertical boring machines2. The safety mechanisms on the machine, and the procedure for checking that they function correctly3. Operation of the machine controls in both hand and power modes, and how to stop the machine in an emergency4. The personal protective equipment that needs to be worn, and where this can be obtained5. The hazards associated with the vertical boring operations, and how they can be minimised6. The importance of keeping the work area clean and tidy7. Where to obtain the component drawings, specifications and/or job instructions required for the components to be



points and system of tolerancing10. The application of a range of vertical boring machines and vertical boring attachments11. The various vertical boring techniques that can be used to produce the required shapes, and the types of vertical

boring tools required (boring tools, turning tools, chamfering tools, recessing tools, form tools, drills, reamers, taps, milling cutters and grinding wheels)

12. The methods that can be used to position the workpiece in relation to the vertical boring cutters and tools13. The effects of backlash in machine slides and screws, and how this can be overcome14. How to handle and store cutting tools safely and correctly (turning and boring tools, milling cutters, grinding

wheels)15. Factors which affect the selection of cutting feeds and speeds, and the depth of cut that can be taken (workpiece


overcome21. How to recognise machining faults and identify when cutters need re-sharpening or grinding wheels need dressing22. The quality control procedures used, inspection checks that need to be carried out, and the equipment that will

need to be used23. The problems that can occur with the vertical boring activities, and how these can be overcome24. The extent of your own authority and whom you should report to when you have problems you cannot resolve


107


performanceevidence 2



required)evidence typedate apply checks and practices during machining activities (all)machine guards in place and correctly adjustedcomponents held securelycutting tools in suitable condition safe working practicesmachine settings adjustedcomponents meet specificationproduce machined components covering (ten)external diameters internal diametersindexed or rotated formsrecesses and groovesexternal taperstaper boresdrilled holesreamed holesmilled facesmilled slotsground diametersstepsground facesthreadsradii/chamfers

turned faces

machine components (one)ferrousnon-ferrousnon-metallicproduce components within quality and accuracy standards (all)free from false tool cuts, burrs or sharp edgesdimensional tolerance BS4500 or BS 1916 grade 7surface finish 63µin or 1.6µmflat/squareness 0.001” per inch /0.025mm per25mmreamed & bored holes within H8angles ± 0.5 degree


108





required)evidence typedate checks for accuracy during production (five)external diameters

internal diameters

lengths/depthsreamed hole size/fittapers/anglesthread fitslot/recess widthsurface finishflatness of facessquareness of faces


Candidate: Date:

Assessor: Date:


109

Unit No 20: Setting Electro Discharge Machines for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up electro discharge machines, such as spark erosion or wire erosion machines, in accordance with approved procedures. This involves selecting the appropriate workholding devices, and mounting and positioning them to the machine in the correct location for the type of operation being carried out. You will also be expected to select the appropriate electrodes or wires to use, check them for defects, and mount and secure them to the relevant parts of the machine.

You will be expected to set the electrical conditions; wire or electrode feed rate, dielectric flow rate, filtration and fume extraction systems. You must produce trial cuts, and prove the machine is working satisfactorily before declaring the installation ready for production. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.

Your responsibilities will require you to comply with organisational policy and procedures for the machine setting activities undertaken, and to report any problems with the machines, equipment or setting up activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting up procedures used. You will understand the electro discharge machine used, and its application, and will know about the workholding devices, electrodes, relevant materials, consumables and setting up procedures, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the work output is to the required specification.




110

Unit No 20: Setting Electro Discharge Machines for Production Performance statements:




● ensure correctly adjusted machine guards are in place● electrode or wire is of the correct type and in a suitable

condition

● hold components securely without distortion

● apply safe working practices at all times2. Prepare one of the following types of electro discharge machine in readiness for production:

● spark erosion ● wire erosion3. Position and secure workpieces to machine table, to include all of the following:

● clamping direct to machine table● pneumatic or magnetic table • machine vice (eg. plain, swivel, universal)


● chucks (eg. 3 or 4 jaw)● ancillary indexing device

4. Select and mount electrodes for roughing and finishing, to include one of the following: ● plain electrodes profile electrodes

● hollow electrodes● wire

5. Set up the machine in accordance with instructions and specifications, to include all of the following:● electrical conditions (current density, spark frequency) ● alignment of electrodes ● wire tension● wire speeds● filtration equipment

● linear feeds and speeds● dielectric flow rates ● ventilation and fume extraction

● correct threading of wire through wire guides and feed mechanisms

● safety mechanisms/devices6. Set up the machine to produce internal and external profiles that include six of the following:

● flat faces● square faces

● convex forms profile forms

● radii/arcs● slots

● square/rectangular forms● angular faces

● parallel faces ● concave forms

● holes ● cavities

● threads● engraving

● other special activities

7. Machine components made from one of the following types of material:● ferrous● non-ferrous

8. Make trial components to prove the machine is operating to required specification, to include all the following:● components to be free from false starts and sharp edges● tolerance to BS 4500 or BS 1916 Grade 7● surface texture 32 µin or 0.8µm or 18VDI


111

Unit No 20: Setting Electro Discharge Machines for Production Knowledge statements:


1. The specific safety precautions to be taken when setting up workholding devices and electrodes or wires on electro discharge machines

2. The hazards associated with electro discharge operations (moving parts of machinery, electrical components, handling dielectrics, fumes) and how they can be minimised

3. How to start and stop the machine in normal and emergency situations4. The importance of ensuring the machine is isolated from the power supply before mounting electrodes, wires and


and tidy6. The basic principles of operation of the various electro discharge machines, and typical operations that they can

perform7. How to handle and store electrodes and wires safely and correctly8. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing10. Terminology used in electro discharge machining in relation to the activities undertaken11. The range of eroded features that are produced on the electro discharge machines12. The range of workholding methods and devices that are used on electro discharge machines13. The methods of mounting and setting the workpiece in/on the workholding devices, and the tools and equipment

that can be used14. The different types of electrodes and wires that are used, and how they are selected, prepared and mounted to the

machine tool holding devices15. Factors that determine current density, spark frequency, wire speeds and feeds, or linear feeds and speeds16. How the various types of material will affect the feeds and speeds that can be used17. The type of dielectrics that are used; filtration requirements; and precautions to be taken when handling and using

them18. How to set up the various machines for the particular operations being performed19. The need to conduct trial runs, and to check that the machine is set up and running safely and correctly20. Problems that can occur with setting up the electrodes or wires, workholding devices, and machine operating



112





required)evidence typedate carry out activities during setting up (all)machine guards in place and correctly adjustedcomponents held securelyelectrode/wire correct type and suitable condition machine guards in place and correctly adjustedprepare electro discharge machine for production (one)spark erosionwire erosionposition and secure workpiece to machine table (all)clamping to machine tablepneumatic/magnetic tablemachine viceangle platevee block and clampsfixtureschucks (3 or 4 jaw)ancillary indexing deviceselect and mount electrodes for roughing and finishing (one)plain electrodesprofile electrodeshollow electrodes

wire

set up machine in accordance with instructions and specifications (all)electrical conditionswire tensionwire speedsfiltration equipmentlinear feeds and speedsdielectric flow ratesventilation / fume extractionalignment of electrodescorrect threading wire through guides and mechanismssafety mechanisms/devices


113





required)evidence typedate set up machine to produce internal and external profiles (six)flat faces square facesparallel facesconcave formsconvex formsprofile formsholescavitiesradii/arcsslotsthreadsengravingsquare/rectangular formsangular formsother special activitiesmachine components (one)ferrousnon-ferrousmake trial components to specification (all))free from false starts and sharp edgestolerance to BS4500/Bs1916 Grade 7surface texture 32µin or 0.8µm or 18VDI


Candidate: Date:

Assessor: Date:


114

Unit No 21: Machining Components using Electro Discharge Machines

Unit Summary

This unit identifies the competencies you need to carry out electro discharge machining operations, using spark erosion or wire erosion machines, in accordance with approved procedures. You will be required to check that the machine is ready for the operations to be performed, and that all the required components, consumables and measuring equipment is available. You will be expected to produce a range of component shapes, such as internal and external profiles, that have flat, square, parallel, and tapered faces, square/rectangular forms, concave and convex forms, holes, slots, radii/arcs, cavities and special forms.

You must operate the machine in line with safe working practices and approved procedures, and continuously monitor the erosion operations, making any necessary adjustments to settings in order to ensure that the work output is to the required quality and accuracy. Meeting production targets will be an important issue, and your production records must show consistent and satisfactory performance.

Your responsibilities will require you to comply with organisational policy and procedures for the electro discharge machining activities undertaken, and to report any problems with the equipment or activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying electro discharge machining procedures. You will understand the electro discharge process undertaken, and its application, and will know about the equipment, materials and consumables, in adequate depth to provide a sound basis for carrying out the activities to the required specification.




115

Unit No 21: Machining Components using Electro Discharge MachinesPerformance statements:



You must: 1. Ensure that you apply all the following checks and practices at all times during the machining activities:

• machine guards are in place and correctly adjusted• components are held securely without distortion• electrodes or wires are maintained in a usable condition• safe working practices are observed• machine settings are adjusted to maintain the required accuracy• components produced meet specification

2. Operate one of the following types of electro discharge machine:● spark erosion ● wire erosion

3. Rough and finish components which include six of the following features:● flat faces● square faces

● concave forms● convex forms

● profile forms● cavities

● square/rectangular forms● angular faces

● parallel faces● threads

● holes● engraving

● radii/arcs● slots

● other special activities

4. . Produce components within all the relevant quality and accuracy standards: ● components to be free from false starts and sharp edges● tolerance to BS 4500 or BS 1916 Grade 7● surface texture 32 µin or 0.8µm or 18VDI

5. Machine components made from one of the following types of material:ferrousnon-ferrous

6. Carry out the necessary checks during production for accuracy of four of the following:● dimensions● parallelism● angle/taper● squareness● surface texture

profile


116

Unit No 21: Machining Components using Electro Discharge MachinesKnowledge statements:


1. The safe working practices and procedures that need to be followed while operating electro discharge machines2. The hazards associated with the electro discharge machining operations (such as moving machine parts, electrical

components, handling dielectrics, fumes) and how they can be minimised3. The safety mechanisms on the machine, and the procedure for checking that they function correctly4. Operation of the machine controls in both hand and power modes, and how to stop the machine in an emergency5. The personal protective equipment that needs to be worn, and where this can be obtained6. The importance of keeping the work area clean and tidy7. Where to obtain the component drawings, specifications and/or job instructions required for the components to be



points and system of tolerancing10. Terminology used in electro discharge machining in relation to the activities undertaken11. The various erosion operations that are used to produce the required forms, and the types of electrodes or wires

used12. How to dress and reshape electrodes, and the equipment to be used13. The methods that can be used to position the workpiece in relation to the electrodes/wire, and the equipment that is

used14. The importance of checking the position and alignment of the workpiece before commencing the erosion operations,

and the tools and equipment that are used15. The effects of backlash in machine slides and screws, and how this can be overcome16. How to handle and store electrodes and wires safely and correctly17. Factors which affect the selection of electrode or wire feeds and speeds (material type, finish and tolerance required)18. The application of roughing and finishing cuts, and the effect on electrode life, surface finish and dimensional

accuracy19. The reason for using dielectrics, and the type of fluid used20. The effects of clamping the workpiece, and how this can cause distortion in the finished components21. How to recognise erosion faults and identify when electrodes need changing22. The quality control procedures used, inspection checks that need to be carried out, and the equipment that will need

to be used23. The problems that can occur with the electro discharge machining activities, and how these can be overcome24. The extent of your own authority and whom you should report to when you have problems that you cannot resolve


117





required)evidence typedate apply checks and practices during machining activities (all)machine guards in place and correctly adjustedcomponents held securelyelectrodes or wires in suitable condition safe working practicesmachine settings adjustedcomponents meet specificationoperate electro discharge machine (one)spark erosionwire erosionrough and finish components including (six)flat facessquare facesparallel facesthreadsconcave formsconvex formsholesengravingprofile formscavitiesradii/arcsslotssquare/rectangular formsangular facesother special activitiesproduce components within quality and accuracy standards (all)free from false starts and sharp edgestolerance to BS4500/BS1916 Grade 7surface texture 32µin or 0.8µm or 1.8VDImachine components (one)ferrousnon-ferrouschecks for accuracy during production (four)dimensionsparallelismangle/tapersquarenesssurface textureprofile


Candidate: Date:

Assessor: Date:


118

Unit No 22: Setting Grinding Machines for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up grinding machines, such as surface grinding, external cylindrical grinding, internal cylindrical, universal, centreless, profile and thread grinding machines, in accordance with approved procedures. You will be expected to set up the machines to grind a range of component shapes, such as internal and external parallel, stepped and tapered diameters, flat, parallel, square and angular faces, steps, slots, radii, chamfers, threads and special forms. This involves selecting the appropriate workholding devices, and mounting and positioning them to the machine in the correct location for the type of operation being carried out.

You will also be expected to select the appropriate grinding wheels to use, check them for defects, balance them when appropriate, and mount and secure them to the machine spindle. You will be expected to prepare the grinding wheels for operation by ‘trueing up’ and dressing the wheels, and creating any necessary relief or form as applicable to the operation to be performed. You must set up the appropriate mechanisms, stops and controls for feeds and speeds, as applicable for the particular operations and machine type used. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.

Your responsibilities will require you to comply with organisational policy and procedures for the machine setting activities undertaken, and to report any problems with the grinding machines, equipment or setting up activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting up procedures used. You will understand the grinding machine used, and its application, and will know about the workholding devices, grinding wheels, wheel forming, relevant materials, consumables and setting up procedures, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the work output is to the required specification.



119

Unit No 22: Setting Grinding Machines for Production Performance statements:



You must: 1. Carry out all the following activities during setting up:● ensure the grinding wheels are correctly dressed/formed and in a usable condition● ensure machine guards are in place and correctly adjusted● apply safe working practices at all times ● hold components securely without distortion2. Prepare one of the following types of grinding machine in readiness for production:

● horizontal surface ● vertical surface

● external cylindrical ● internal cylindrical

● universal● centreless

● thread grinding

3. Position and secure workpieces using four of the following workholding methods and devices:● chucks● collets● centres

● face plate● machine vices● power chucks

● clamps● angle plates● vee blocks

● work rests● control stops● fixtures

● injector mechanisms● magnetic blocks● pots

4. Select and mount grinding wheels, to include all of the following:● selecting grinding wheels for specific materials and applications (grain size, grade, structure, bond)● mounting wheels (paper washers, flanges, locking pressure)● testing wheels for cracks ● balancing wheels, where appropriate

5. Prepare gear grinding wheels to include carrying out two of the following:● dressing and ‘trueing up’ grinding wheels● wheel forming (chamfers, radii, angular forms, profiles)

● relieving the wheel sides ● dressing and ‘trueing up’ control wheels

6. Set up grinding machines to grind five of the following forms, as applicable to the machine type:● flat faces● vertical faces ● parallel faces● faces square to each other ● shoulders and faces ● slots

● parallel diameters● tapered diameters● counterbores● tapered bores● parallel bores● profile forms

● other thread forms● vee form threads● left hand threads● right hand threads● single start threads● multi-start threads

● internal threads● external threads● angular faces

7. Grind components made from one of the following types of material: ● ferrous ● non-ferrous ● non-metallic

8. Grind trial components to prove the machine is operating to required specification, to include all the following:● tolerance to BS 4500 or BS 1916 Grade 5● surface texture 8 µin or 0.2µm ● components to be free from false grinding cuts, burrs and sharp edges


120

Unit No 22: Setting Grinding Machines for Production Knowledge statements:


1. The specific safety precautions to be taken when setting up workholding devices and grinding wheels on grinding machines (such as cylindrical, internal, surface, centreless and thread grinding)

2. Your duties and responsibilities under The Abrasive Wheels Regulations, with particular reference to the mounting of abrasive wheels

3. The hazards associated with grinding (such as moving parts of machinery, sparks/airborne particles, bursting grinding wheels, insecure components) and how they can be minimised

4. How to start and stop the machine in normal and emergency situations5. The importance of ensuring the machine is isolated from the power supply before mounting grinding wheels and


and tidy7. The basic operation of the various grinding machines, and typical operations that they can perform8. How to handle and store grinding wheels safely and correctly9. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing11. Terminology used in grinding in relation to the activities undertaken12. The range of work holding methods and devices that are used on grinding machines13. The methods of mounting and setting the workpiece in/on the workholding devices, and the tools and equipment

that can be used14. The various grinding operations that are used to produce the required profiles, and the types of wheels that are used15. How to check that the grinding wheels are in a safe and serviceable condition (free from damage, cracks, correctly

balanced)16. The methods of mounting and securing the grinding wheels to the machine spindles17. Methods of forming the wheels to the required profile (use of pantograph, diamond dressing units, thread crushing

rolls)18. The need for ‘trueing up’ and dressing of wheels to prevent glazing and burning of workpiece19. How to set up the various machines for the particular operations being performed20. How the various types of material will affect the feeds and speeds that can be used21. The application of cutting fluids with regard to a range of different materials22. The need to conduct trial runs, and to check that the machine is set up and running safely and correctly23. Problems that can occur with setting up of the grinding wheels, workholding devices and machine operating



121





required)evidence typedate carry out activities during setting up (all)wheels are correctly dressed/formed and usablemachine guards in place and correctly adjustedcomponents held securelysafe working practicesprepare grinding machines in readiness for production (one)horizontal surfacevertical surfaceexternal cylindricalinternal cylindricaluniversalcentrelessthread grindingposition and secure workpieces (four)chuckscolletscentresface platemachine vicespower chucksclampsangle platesvee blockswork restscontrol stopsfixturesinjector mechanismsmagnetic blockspotsselect and mount grinding wheels (all)select grinding wheels mounting wheelstesting wheels for cracksbalancing wheelsprepare grinding wheels (two)dressing and truing up grinding wheelswheel formingrelieving wheel sidesdressing and truing up control wheels


122





required)setting up grinding machines to grind forms (five)flat facesvertical facesparallel facesfaces square to each othershoulders and facesslotsparallel diameterstapered diameterscounterborestapered boxesparallel boresprofile formsother thread formsvee form threadsleft hand threadsright hand threadssingle start threadsmulti-start threadsinternal threadsexternal threadsangular threadsgrind components (one)ferrousnon-ferrousnon-metallicgrind trial components to required specification (all)tolerance to BS 4500/BS 1916 Grade 5surface texture 8 µin or 0.2µmfree from cuts, burrs, sharp edges


Candidate: Date:

Assessor: Date:


123

Unit No 23: Machining Components using Grinding Machines

Unit Summary

This unit identifies the competencies you need to carry out grinding operations, using machines such as horizontal and vertical surface grinding, external cylindrical, internal cylindrical, universal, centreless, profile and thread grinding machines, in accordance with approved procedures. You will be required to check that the machine is ready for the operations to be performed, and that all the required components, consumables and measuring equipment is available. You will be expected to grind a range of component shapes, such as internal and external parallel, stepped and tapered diameters, flat, parallel, square and angular faces, steps, slots, radii, chamfers, threads and special forms.

You must operate the machine in line with safe working practices and approved procedures, and continuously monitor the grinding operations, making any necessary adjustments to settings in order to ensure that the work output is to the required quality and accuracy. Meeting production targets will be an important issue, and your production records must show consistent and satisfactory performance.

Your responsibilities will require you to comply with organisational policy and procedures for the grinding activities undertaken, and to report any problems with the grinding equipment or grinding activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying grinding procedures. You will understand the grinding process undertaken, and its application, and will know about the equipment, materials and consumables, in adequate depth to provide a sound basis for carrying out the activities to the required specification.

You will understand the safety precautions required when working with the grinding machine and its associated grinding wheels and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.



124

Unit No 23: Machining Components using Grinding MachinesPerformance statements:




• appropriate machine guards are in place and correctly adjusted• components are held securely without distortion• grinding wheels are maintained correctly dressed/formed and in a usable condition• safe working practices are observed• machine settings are adjusted to maintain the required accuracy• components produced meet specification

2. Operate two of the following types of grinding machine:● horizontal surface● vertical surface

● external cylindrical● internal cylindrical

● universal● centreless

● thread grinding● profile grinding

3. Finish grind components which include six of the following features:● flat faces● vertical faces ● parallel faces● faces square to each other ● shoulders and faces ● slots

● parallel diameters● tapered diameters● counter bores● tapered bores● parallel bores● profile forms

● other thread forms● vee form threads● left hand threads● right hand threads● single start threads● multi-start threads

● internal threads● external threads● angular faces

4. Produce components with dimensional accuracy, form and surface texture within all the following standards:● tolerance to BS 4500 or BS 1916 Grade 5● surface texture 8 µin or 0.2µm ● components to be free from false grinding cuts, burrs and sharp edges

5. Grind components made from one of the following types of material:● ferrous● non-ferrous ● non-metallic

6. Carry out the necessary checks for accuracy during production of at least four of the following:● dimensions● parallelism● squareness● profile● concentricity

● thread form● surface texture● angle/taper● ovality/lobbing


125

Unit No 23: Machining Components using Grinding MachinesKnowledge statements:


1. The safe working practices and procedures that need to be followed while operating grinding machines2. Your duties and responsibilities under The Abrasive Wheels Regulations, with particular reference to the mounting of

abrasive wheels3. The hazards associated with the grinding operations (moving machine parts, sparks/airborne particles, bursting

grinding wheels, insecure workpieces) and how they can be minimised4. The safety mechanisms on the machine, and the procedure for checking that they function correctly5. Operation of the machine controls in both hand and power modes, and how to stop the machine in an emergency6. The personal protective equipment that needs to be worn, and where this can be obtained7. The importance of keeping the work area clean and tidy8. Where to obtain the component drawings, specifications and/or job instructions required for the components to be



points and system of tolerancing11. Terminology used in grinding in relation to the activities undertaken12. The various grinding operations that are used to produce the required forms, and the types of grinding wheels used13. How to dress and reshape grinding wheels, and the equipment to be used14. The methods that can be used to position the workpiece in relation to the grinding wheel15. The importance of checking the concentricity and/or position/alignment of the workpiece before grinding, and the

tools and equipment that are used16. The effects of backlash in machine slides and screws, and how this can be overcome17. How to handle and store grinding wheels safely and correctly18. Factors which affect the selection of grinding wheel feeds and speeds, and the depth of cut that can be taken (wheel

size, material type, finish and tolerance required)19. The application of roughing and finishing cuts, and the effect on wheel life, surface finish and dimensional accuracy20. The reason for using cutting fluids, and the type of fluid used21. The effects of clamping the workpiece, and how this can cause distortion in the finished components22. How to recognise grinding faults and identify when grinding wheels need re-dressing/forming23. The quality control procedures used, inspection checks that need to be carried out, and the equipment that will need

to be used.24. The problems that can occur with the grinding activities, and how these can be overcome25. The extent of your own authority and whom you should report to when you have problems that you cannot resolve


126





required)evidence typedate apply checks and practices during machining activities (all)machine guards in place and correctly adjustedcomponents held securelywheels maintained correctlysafe working practicesmachine settings adjustedcomponents meet specificationoperate grinding machine (two)horizontal surface vertical surfaceexternal cylindricalinternal cylindricaluniversalcentrelessthread grindingprofile grindingfinish grind components including (six)flat facesvertical facesparallel facesfaces square to each othershoulders and facesslotsparallel diameterstapered diameterscounterborestapered boxesparallel boresprofile formsother thread formsvee form threadsleft hand threadsright hand threadssingle start threadsmulti-start threadsinternal threadsexternal threadsangular threadsproduce components within quality and accuracy standards (all)tolerance to BS4500/ BS1916 Grade 5surface texture 8µin or 0.2µmfree from cuts, burrs, sharp edgesgrind components (one)ferrousnon-ferrousnon-metallic


127





required)evidence typedate checks for accuracy during production (four)dimensionsparallelismsquarenessprofileconcentricitythread formsurface textureangle/taperovality/lobbing


Candidate: Date:

Assessor: Date:


128

Unit No 24: Setting Honing and Lapping Machines for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up honing and lapping machines, such as horizontal, vertical honing machines, rotary and reciprocal lapping machines, in accordance with approved procedures. This involves selecting the appropriate workholding devices, and mounting and positioning them to the machine in the correct location for the type of operation being carried out. You will be expected to select the appropriate honing mandrels, stones, discs and grit to use, check them for defects and mount and secure them to the machine spindle. You will also be expected to mount the workpiece, and to check that it is correctly positioned and aligned before starting the honing or lapping operations.

You must set up the appropriate mechanisms, stops and controls for stroke lengths, stroke over-run, speed of stroke, RPM, and stone pressure, as applicable for the particular operations and machine type used. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.

Your responsibilities will require you to comply with organisational policy and procedures for the machine setting activities undertaken, and to report any problems with the honing and lapping machines, equipment or setting up activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting up procedures used. You will understand the honing and lapping machines used, and their application, and will know about the workholding devices, honing stones, equipment, relevant materials, consumables and setting up procedures, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the work output is to the required specification.



129

Unit No 24: Setting Honing and Lapping Machines for Production Performance statements:



You must: 1. Carry out all the following activities during setting up:

• ensure the machine guards are in place and correctly adjusted• check that the honing stones or discs are in a usable condition• apply safe working practices at all times • hold components securely without distortion

2. Prepare one of the following types of honing or lapping machine in readiness for production: ● horizontal honing ● vertical honing ● rotary disc lapping ● reciprocating machines

3. Position and secure workpieces, using four of the following workholding methods and devices: ● chucks● collets

● pots● vee-blocks

● magnetic chucks ● magnetic blocks

● face plate● clamps

● jigs/fixtures ● angle plates

4. Select, prepare and mount all the following for honing machines: ● selecting mandrels and wedges to suit bore size and through or blind hole● selecting honing stones for specific materials and applications (roughing, finishing, polishing) ● checking stones for damage

or. select, prepare and mount all the following for lapping machines: ● selecting discs/pads for specific materials and applications (roughing, finishing, polishing) ● selecting appropriate grits for specific materials and applications (roughing, finishing, polishing)● checking discs for damage

5. Prepare honing or lapping machines, to include all the following, as applicable to the machine type:● RPM or reciprocating speed● stroke length

● stroke over-run length● stroke speed

● stone or disc pressure

6. Set up honing machines to finish all of the following features:● through holes ● blind holes ● tapered holes

or set up lapping machines to finish all of the following features:● flat faces ● parallel faces ● angular faces

7. Hone or lap components made from one of the following types of material:● ferrous ● non-ferrous

8. Machine trial components to prove machine is operating to required specification, to include all the following: ● tolerance to BS 4500 or BS 1916 Grade 5● surface texture 8 µin or 0.2µm ● components to be free from stone marks, burrs and sharp edges


130

Unit No 24: Setting Honing and Lapping Machines for Production



1. The specific safety precautions to be taken when setting up workholding devices and honing/lapping equipment on machines (such as horizontal, vertical, rotary disc and reciprocating honing and lapping machines)

2. The hazards associated with honing and lapping (such as moving parts of machinery, airborne particles, insecure components) and how they can be minimised

3. How to start and stop the machine in normal and emergency situations4. The importance of ensuring the machine is isolated from the power supply before mounting honing mandrels, stones

and workholding devices5. The importance of wearing the appropriate protective clothing and equipment, and of keeping the work area clean

and tidy6. The basic operation of the various honing and lapping machines, and typical operations that they can perform7. How to handle and store honing and lapping equipment and stones safely and correctly8. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing10. Terminology used in honing and lapping in relation to the activities undertaken11. The range of work holding methods and devices that are used on honing and lapping machines12. The methods of mounting and setting the workpiece in/on the workholding devices, and the tools and equipment

that can be used13. The various honing and lapping operations that are used to produce the required profiles, and the types of stones,

discs and grits that are used14. How to check that the honing mandrels, wedges and stones are in a safe and serviceable condition (free from

damage, correct type, correctly fitted and secured)15. The methods of mounting and securing the mandrels and discs to the machine spindles16. How to set up the various machines for the particular operations being performed (stroke length, stroke speed, RPM,

stone pressure)17. How the various types of material will affect the feeds and speeds that can be used18. The application of cutting fluids with regard to a range of different materials19. Filtration requirements, and how to recognise when filters require changing/cleaning20. The need to conduct trial runs, and to check that the machine is set up and running safely and correctly21. Problems that can occur with setting up of the honing and lapping equipment, workholding devices and machine



131





required)evidence typedate activities during setting uphoning stones/discs in useable conditionmachine guards in place and correctly adjustedcomponents held securelysafe working practicesprepare honing/lapping machine for production (one)horizontal honingvertical honingrotary disc lappingreciprocating machinesposition and secure workpieces using workholding methods and devices (four)chuckscolletspotsvee blocksmagnetic chucksmagnetic blocksface platesclampsjigs/fixturesangle platesselect, prepare and mount honing machines (all)select mandrels/wedgesselect honing stonescheck stones for damageOR select, prepare and mount lapping machines (all)select discs/padsselect grits for specific materialcheck discs for damageprepare honing/lapping machines (all)rpm or reciprocating speedstroke lengthstroke over-run lengthstroke speed stone or disc pressureset up honing machines to finish (all)through holesblind holestapered holesOR set up lapping machines to finish (all) flat facesparallel facesangular faceshone or lap components (one)ferrousnon-ferrous

evidence record sheet performance performance performance additional


132

evidence 1 evidence 2 evidence 3 performance evidence (if

required)evidence typedate machine trial components to required specification (all)tolerance to BS4500/BS1916 Grade 5surface texture 8µin or 0.2µmfree from stone marks, burrs, sharp edges


Candidate: Date:

Assessor: Date:


133

Unit No 25: Machining Components using Honing and Lapping Machines

Unit Summary

This unit identifies the competencies you need to carry out honing and lapping operations using horizontal or vertical honing machines and lapping machines, in accordance with approved procedures. You will be required to check that the machine is ready for the operations to be performed, and that all the required components, consumables and measuring equipment is available. You will be expected to hone/lap a range of components, which will include through holes, blind holes and flat surfaces.

You must operate the machine in line with safe working practices and approved procedures, and continuously monitor the honing and lapping operations, making any necessary adjustments to settings, in order to ensure that the work output is to the required quality and accuracy. Meeting production targets will be an important issue, and your production records must show consistent and satisfactory performance.

Your responsibilities will require you to comply with organisational policy and procedures for the honing and lapping activities undertaken, and to report any problems with the equipment or activities that you cannot resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying honing and lapping procedures. You will understand the honing and lapping process undertaken, and its application, and will know about the equipment, materials and consumables, in adequate depth to provide a sound basis for carrying out the activities to the required specification.




134

Unit No 25: Machining Components using Honing and Lapping MachinesPerformance statements:



You must: 1. Ensure that you apply all the following checks and practices at all times during the machining activities:

• appropriate machine guards are in place and correctly adjusted• components are held securely without distortion• honing stones or discs are maintained in a usable condition• safe working practices are observed• machine settings are adjusted, as necessary, to maintain the required accuracy• components produced meet specification

2. Operate one of the following types of honing or lapping machine:● horizontal honing● vertical honing

● rotary disc lapping● reciprocating machine

3. Rough, finish and polish components which includes all of the following (for honing machines): ● through holes ● blind holes ● tapered holes

or rough, finish and polish components which includes all of the following (for lapping machines): ● flat faces ● parallel faces ● angular faces

4. Produce components with dimensional accuracy, form and surface texture within all the following standards:● tolerance to BS 4500 or BS 1916 Grade 5● surface texture 8 µin or 0.2µm ● components to be free from stone/disc marks, burrs and sharp edges

5. Hone and lap components made from one of the following types of material: ● ferrous● non-ferrous

6. Carry out all of the following checks during production for accuracy (using honing machines):● dimensions● parallelism

● surface texture● ovality/lobbing

or carry out all of the following checks during production for accuracy (using lapping machines):● dimensions● parallelism

● surface texture● flatness


135

Unit No 25: Machining Components using Honing and Lapping MachinesKnowledge statements:


1. The safe working practices and procedures that need to be followed while operating honing and lapping machines2. The hazards associated with the honing and lapping operations (such as moving machine parts, airborne particles,

insecure workpieces) and how they can be minimised3. The safety mechanisms on the machine, and the procedure for checking that they function correctly4. Operation of the machine controls in both hand and power modes, and how to stop the machine in an emergency5. The personal protective equipment that needs to be worn, and where this can be obtained6. The importance of keeping the work area clean and tidy7. Where to obtain the component drawings, specifications and/or job instructions required for the components to be



points and system of tolerancing10. Terminology used in honing and lapping in relation to the activities undertaken11. The various honing and lapping operations that are used to produce the required forms, and the types of stones and

abrasives used12. The methods that can be used to position the workpiece in relation to the honing mandrel13. The importance of checking the concentricity and/or position/alignment of the workpiece before honing, and the

tools and equipment that are used14. How to adjust the equipment to correct taper in bores and achieve workpiece tolerances15. How to handle and store honing and lapping stones and equipment safely and correctly16. Factors which affect the selection of honing and lapping stroke speeds, RPM and stone pressures (stock removal,

material type, finish and tolerance required)17. The application of roughing and finishing cuts, and the effect on stone life, surface finish and dimensional accuracy18. The reason for using cutting fluids; the type of fluid used and filtration requirements19. The effects of clamping the workpiece, and how this can cause distortion in the finished components20. How to recognise honing and lapping faults and identify when stones need replacing21. The quality control procedures used, inspection checks that need to be carried out, and the equipment that will need

to be used22. The problems that can occur with the honing and lapping activities, and how these can be overcome23. The extent of your own authority and whom you should report to when you have problems that you cannot resolve


136





required)evidence typedate apply checks and practices during machining activities (all) machine guards adjustedmachine settings adjustedcomponents meet specificationhoning stones/discs in useable conditionsafe working practicescomponents held securelyrough, finish and polish components {honing machines} (all)through holesblind holestapered holesor rough, finish and polish components {lapping machines} (all)flat facesparallel facesangular facesproduce components with dimensional accuracy (all)tolerance to BS4500/BS1916 Grade 5surface texture 8µin or 0.2µmfree from stone/disk marks, burrs/sharp edgeshone and lap components (one)ferrousnon-ferrouscarry out checks during production for accuracy {honing machines} (all)dimensions parallelismsurface texture ovality/lobbingOR carry out checks during production for accuracy {lapping machines} (all)dimensionsparallelismsurface textureflatness


Candidate: Date:

Assessor: Date:


137

Unit No 26: Setting Broaching Machines for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up horizontal and/or vertical broaching machines for production, in accordance with approved procedures. This will involve selecting the appropriate workholding devices and securing them to the machine, and mounting and setting the workpiece in correct relationship to the broaching tool. You will be expected to select the appropriate broaching tools, check that they are in a usable condition, and mount and secure them to the relevant tool holding devices.

You will also need to set the machine operating parameters to produce the workpiece to the required specification. This will involve setting the appropriate stroke length, pulling pressure and feed required. You must produce trial cuts and prove that the machine is working satisfactorily before declaring the machine ready for production. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.


Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting up procedures used. You will understand the broaching machine used and its application, and will know about the workholding devices, broaching tools, relevant materials, consumables and setting up procedures, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the work output is produced to the required specification.



138

Unit No 26: Setting Broaching Machines for Production Performance statements:




• ensure machine guards are in place and correctly adjusted• hold components securely without distortion• apply safe working practices at all times• check that the broaching tools are in a suitable condition

2. Set up one of the following types of machine:● horizontal broaching machine ● vertical broaching machine

3. Set up the workpiece and broach, to include all of the following: ● selecting and setting the appropriate work holding device● locating and, where appropriate, securing the workpiece in the holding device● fitting and aligning the appropriate broach● aligning the workpiece in relationship to machine axis

4. Set up machine in accordance with instructions and specifications, to include setting all of the following:● stroke position and length mechanisms● machine guards/safety mechanisms● broach pulling pressure

● cutting fluid flow rate ● stroke speed/feed

5. Set up the machine to produce internal and external profiles that include four of the following:● keyways● flat sided holes● square holes● hexagonal holes

● octagonal holes● splines● serrations● other/special forms

6. Machine components made from one type of material from the following:● ferrous● non-ferrous● non-metallic

7. Machine trial components to prove machine is operating to required specification, to include all the following: ● dimensional tolerance equivalent to BS 4500 or BS 1916 Grade 7● surface finish 63 µin or 1.6µm ● components to be free from false tool cuts, burrs and sharp edges


139

Unit No 26: Setting Broaching Machines for Production Knowledge statements:


1. The specific safety precautions to be taken when setting up workholding devices and accessories, workpiece and broaching tools

2. The hazards associated with broaching (such as moving parts of machinery, handling broaching tools, handling cutting fluids, tool breakage, insecure components) and how they can be minimised

3. How to start and stop the machine in normal and emergency situations4. The importance of ensuring the machine is isolated from the power supply before mounting broaching tools and


and tidy6. The basic principles of operation of the broaching machine and its accessories, and typical operations that they can

perform7. How to handle and store broaching tools safely and correctly8. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing10. Terminology used in broaching in relation to the activities undertaken11. The range of workholding methods and devices that are used on broaching machines (jigs and fixtures, direct

clamping to machine table)12. The methods of mounting and setting the workpiece in/on the workholding devices, and the tools and equipment

that can be used13. The different types of broaching tools that are used, and how they are selected, prepared and mounted to the

machine tool holding devices14. Factors which determine pulling pressure and feeds to be used (material, type of tooling, machine condition,

tolerance and finish required)15. How the various types of materials will affect the feeds that can be used16. The type of cutting fluids that are used, and precautions to be taken when handling and using them17. How to set up the broaching machine and its accessories for the particular operations being performed (setting

stroke length, stroke position, pulling pressure and feed required)18. The need to conduct trial runs, and to check that the machine is set up and producing the components correctly19. Problems that can occur with setting up the workholding devices, tooling and machine operating parameters, and



140





required)evidence typedate carry out activities during setting up (all)machine guards in place and correctly adjustedcomponents held securelysafe working practicesbroaching tools in suitable conditionset up broaching machines (one)horizontal broachingvertical broachingset up workpiece and broach (all)work holding devicelocating/securing workpiece fitting/aligning broachaligning workpiece to axisset up machine in accordance with instructions and specifications (all)stroke position/length mechanismsguards/safety mechanismsbroach pulling pressurecutting fluid flow ratestroke speed/feedset up machine to produce internal and external profiles (four)keywaysflat sided holessquare holeshexagonal holesoctagonal holesspinesserrationsother/special formsmachine components (one)ferrousnon-ferrousnon-metallicmachine trial components to required specification (four)tolerance to BS4500/BS1916 Grade7surface finish 63µin or 1.6µmfree from tool cuts ,burrs, sharp edges


Candidate: Date:

Assessor: Date:


141

Unit No 27: Machining Components using Broaching Machines

Unit Summary

This unit identifies the competencies you need to carry out broaching operations using horizontal or vertical broaching machines, in accordance with approved procedures. You will be required to check that the machine is ready for the operations to be performed and that all the required components/materials and consumables are available. You will be expected to produce a range of components that contain features such as keyways, square holes, hexagonal and octagonal holes, holes with one flat, splines, serrations, and special forms.



Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying machining procedures. You will understand the broaching process, and its application, and will know about the equipment, materials and consumables, in adequate depth to provide a sound basis for carrying out the activities to the required specification.




142

Unit No 27: Machining Components using Broaching MachinesPerformance statements:




• appropriate machine guards are in place and correctly adjusted• components are held securely without distortion• broaching tools are maintained in a suitable condition• safe working practices are observed at all times• machine settings are adjusted, as necessary, to maintain the required accuracy• components produced meet specification

2. Operate one type of machine from the following:● horizontal broaching machine● vertical broaching machine

3. Produce machined components which cover four of the following:● keyways● flat sided holes● square holes● hexagonal holes

● octagonal holes● splines● serrations● other/special forms

4. Machine components made from one type of material from the following:● ferrous● non-ferrous● non-metallic

5. Produce components within all the relevant quality and accuracy standards:● dimensional tolerance equivalent to BS 4500 or BS 1916 Grade 7● surface finish 63 µin or 1.6µm ● components to be free from false tool cuts, burrs and sharp edges

6. Carry out the necessary checks during production for accuracy of five of the following:● dimensions● squareness● spline/serration fit● surface finish● keyway width● keyway position


143

Unit No 27: Machining Components using Broaching MachinesKnowledge statements:


1. The safe working practices and procedures that need to be followed while operating broaching machines2. The safety mechanisms on the machine, and the procedure for checking that they function correctly3. Operation of the machine controls in both hand and power modes, and how to stop the machine in an emergency4. The personal protective equipment that needs to be worn, and where this can be obtained5. The hazards associated with the broaching operations (such as moving parts of machines, handling broaches,

handling cutting oils, insecure components, breakages of broaches) and how they can be minimised6. The importance of keeping the work area clean and tidy7. Where to obtain the component drawings, specifications and/or job instructions required for the components to be



points and system of tolerancing10. The various broaching techniques that can be used to produce the required shapes, and the types of broaches used

(roughing and finishing broaches, high speed steel and tipped broaches)11. The methods that can be used to position the workpiece in relation to the broach12. How to handle and store broaches safely and correctly13. Factors which affect the selection of broaching speeds (workpiece rigidity, machine condition, type of broach being

used, material type, finish and tolerance required)14. How the various types of materials will affect the broaching feeds that can be used15. The application of cutting fluids with regard to a range of different materials16. The effects of clamping the workpiece, and how this can cause distortion in the finished components17. How to recognise broaching faults and identify when tools need re-sharpening18. The quality control procedures used, inspection checks that need to be carried out, and the equipment that will need

to be used19. The problems that can occur with the broaching activities, and how these can be overcome20. The extent of your own authority and whom you should report to when you have problems that you cannot resolve


144





required)evidence typedate checks and practices (all)machine guards adjustedmachine settings adjustedcomponents meet specificationbroaching tools in suitable conditionsafe working practicescomponents held securelyoperate machines (one)horizontal broachingvertical broachingproduce machined components covering (four)keywaysflat sided holessquare holeshexagonal holesoctagonal holessplinesserrationsother/special formsmachine components (one)ferrous non-ferrousnon-metallicproduce components with dimensional accuracy (all) tolerance to BS4500/BS1916 Grade 7 surface finish 63µin or 1.6µmfree from tool cuts, burrs, sharp edgescarry out checks during production for accuracy (five)dimensionssquarenessspine/serration fitsurface finishkeyway widthkeyway position


Candidate: Date:

Assessor: Date:


145

Unit No 28: Setting Metal Spinning Machines for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up metal spinning machines and metal spinning equipment, in accordance with approved procedures. This involves selecting the appropriate workholding devices, and mounting and positioning them to the machine in the correct location for the type of operation being carried out. You will also be expected to select the appropriate metal spinning tools and forming devices, check them for defects, and mount and secure them to the relevant tool holding device or forming device.

You will also be expected to set up and align the workpiece in the correct relationship to the machine spindle, and to set the machine operating parameters to produce the workpiece to the required specification. You must carry out trial forming, and prove the machine is working satisfactorily before declaring the installation ready for production. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.

Your responsibilities will require you to comply with organisational policy and procedures for the machine setting activities undertaken, and to report any problems with the machine, forming device, tools, equipment or setting up activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting up procedures used. You will understand the metal spinning machine used, and its application, and will know about the workholding devices, forming tools, relevant materials, consumables and setting up procedures, in adequate depth to provide a sound basis for carrying out the activities to the required specification.



146

Unit No 28: Setting Metal Spinning Machines for Production Performance statements:




• ensure machine guards are in place and correctly adjusted• check that the metal spinning tools and cutters are in a suitable condition• apply safe working practices at all times • hold components securely without distortion

2. Prepare one of the following metal spinning machines in readiness for production:• hand spinning • special purpose spinning • power spinning

3. Select forming device or method, to include four of the following:● tailstock-mounted back plates● plain formers

● segmental formers● split formers● top slide-mounted rollers ● pre-forms ● on-air

4. Select and mount metal spinning tools and cutters, to include four of the following:● finishing rollers● rough forming rollers

• burnishing tools/skimmers● trimming/cutting tools

• handheld metal/wooden spinning tools● power spinning tools and cutters

5. Set up the machine in accordance with instructions and specifications, to include setting all of the following:● forming template/jig● workpiece● forming tool work rests

● forming tools in tool holding devices● machine guards/safety mechanisms

● feed rates (where appropriate)● spindle speeds

6. Set up the machine to rough and finish internal and external forms, that must include ten of the following:• convex shapes• concave shapes

● bulging/necking ● flanges

● lipping● hemispheres

● re-entrant● trimming

● cones ● cylinders ● joints and joining ● double seaming ● beading 7. Make components from one of the following types of material:

● ferrous ● non-ferrous

8. Make trial components to prove machine is operating to required specification, to include all the following: ● dimensional tolerance equivalent to BS 4500 or BS 1916 Grade 9● surface finish 63µin or 1.6µm ● angles/tapers within +/- 0.5 degree● shape and form comply with template and/or specification requirements ● components to be free from ripples, deformity, burrs and sharp edges


147

Unit No 28: Setting Metal Spinning Machines for Production Knowledge statements


1. The specific safety precautions to be taken when setting up workholding devices, tools and cutters on metal spinning machines

2. The hazards associated with metal spinning machines (such as moving parts of machinery, handling tools and cutters, lifting and moving workpieces, tool breakage, insecure components) and how they can be minimised

3. How to start and stop the machine in normal and emergency situations4. The importance of ensuring the machine is isolated from the power supply before mounting tools, workpieces and


and tidy6. The basic principles of operation of the metal spinning machine, and typical operations that it can perform7. How to handle and store forming tools and cutters safely and correctly8. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing10. Terminology used in metal spinning in relation to the activities undertaken11. The range of workholding methods and devices that are used on metal spinning machines12. The methods of mounting and setting the workpiece on the workholding device, and the tools and equipment that

can be used13. The different types of metal spinning tools and cutters that are used, and how they are selected, prepared and

mounted to the machine tool holding devices14. Factors which determine speeds to be used (material, type of forming tool used, workpiece rigidity, operation being

performed, tolerance and finish required)15. How the various types of materials will affect the speeds and forming pressures that can be used16. How to set up the machine for the particular operations being performed17. The need to conduct trial runs, and to check that the machine is set up and running safely and correctly18. Problems that can occur with setting up the metal spinning tools and cutters, work holding devices and machine



148





required)evidence typedate carry out activities during setting up (all)machine guards in place and correctly adjustedcomponents held securelysafe working practicesmetal spinning tools and cutters in suitable conditionprepare metal spinning machines for production (one)hard spinningspecial purpose spinningpower spinningselect forming device or method (four)plain formerssegmental formerssplit formerstop slide-mounted rollerstailstock-mounted back platespre-formson-airselect and mount metal spinning and cutters (four)finishing rollers rough forming rollersburnishing tools/skimmerstrimming/cutting toolshandheld metal/wooden spinning toolspower spinning tools/cuttersset up machine in accordance with instructions and specifications (all)forming templates/jig workpieceforming tool work restsforming tools in tool holding devicesmachine guards/safety mechanismsfeed ratesspindle speedsset up machine to rough and finish internal and external forms (ten)convex shapesconcave shapesconesflangeslippinghemispheresbulging/neckingre-entranttrimmingcylindersjoints and joiningdouble seamingbeading



149


requiredevidence typedate make components (one)ferrousnon-ferrousmake trial components to required specification (four)tolerance to BS4500/Bs1916 Grade 9surface finish 63µin or 1.6µmangles/tapers +/- 0.5 degreeshape and form to template/specification requirementsfree from ripples, deformity, burrs, sharp edges


Candidate: Date:

Assessor: Date:


150

Unit No 29: Producing Components using Metal Spinning Machines

Unit Summary

This unit identifies the competencies you need to carry out metal spinning operations, in accordance with approved procedures, using metal spinning machines and associated metal spinning attachments. You will be required to check that the machine is ready for the operations to be performed, and that all the required components or materials and consumables are available. You will be expected to produce a range of components that combine a number of different features, such as roughing and finishing forms, producing concave and convex profiles, cones, cylinders, hemispheres, re-entrant, bulging/necking, lipping, beading, flanging, joins and jointing, double seaming and trimming operations.

You will be required to operate the machine in line with safe working practices and approved procedures, and to continuously monitor the spinning operations, making any necessary adjustments, in order to ensure that the work output is to the required quality and accuracy. Meeting production targets will be an important issue, and your production records must show consistent and satisfactory performance.

Your responsibilities will require you to comply with organisational policy and procedures for the spinning activities undertaken, and to report any problems with the spinning activities, equipment or forming tools that you cannot personally resolve, or are outside your permitted authority to, the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying metal spinning procedures. You will understand the metal spinning process, and its application, and will know about the equipment, materials and consumables, in adequate depth to provide a sound basis for carrying out the activities to the required specification.




151

Unit No 29: Producing Components using Metal Spinning MachinesPerformance statements:



You must:1. Ensure that you apply all the following checks and practices at all times during the spinning activities:

machine guards are in place and correctly adjustedcomponents are held securely forming and cutting tools are maintained in a suitable conditionsafe working practices are observedmachine settings are adjusted, as necessary, to maintain the required accuracycomponents produced meet specification

2. Produce components which combine different operations and which cover ten of the following:convex shapesconcave shapesbulging/necking flanges

lippinghemispheresre-entranttrimming

conescylindersjoints and joining

double seamingbeading

4. Make components from one of the following types of material:● ferrous ● non-ferrous

5. Produce components within all the relevant quality and accuracy standards:● dimensional tolerance equivalent to BS 4500 or BS 1916 Grade 9● surface finish 63µin or 1.6µm ● angles/tapers within +/- 0.5 degree● shape and form comply with template and/or specification requirements ● components to be free from ripples, deformity, burrs and sharp edges

6. Carry out the necessary checks during production for accuracy of five of the following:● external diameters● internal diameters● lengths ● depths

● angles● profiles● surface finish


152

Unit No 29: Producing Components using Metal Spinning MachinesKnowledge statements:


1. The safe working practices and procedures that need to be followed while operating metal spinning machines2. The safety mechanisms on the machine, and the procedure for checking that they function correctly3. Operation of the machine controls in both hand and power modes, and how to stop the machine in an emergency4. The personal protective equipment that needs to be worn, and where this can be obtained5. The hazards associated with the metal spinning operations, and how they can be minimised6. The importance of keeping the work area clean and tidy7. Where to obtain the component drawings, specifications and/or job instructions required for the components to be



points and system of tolerancing10. The application of a range of metal spinning machines and metal spinning attachments11. The various metal spinning techniques that can be used to produce the required shapes, and the types of metal

spinning formers, cutters and tools required12. The methods that can be used to position the workpiece in relation to the metal spinning former, cutters and tools13. How to handle and store formers and cutting tools, safely and correctly14. Factors which affect the selection of speeds required, and the pressure that can be put on to the workpiece

(workpiece rigidity, machine condition, type of formers/tooling being used, material type, finish and tolerance required)

15. How the various types of materials will affect the speeds that can be used16. The application of roughing and finishing forms, and the effect on former and tool life, surface finish and dimensional

accuracy17. The effects of clamping the workpiece, and how this can cause distortion in the finished components18. The effects of displacing material, how this can cause warping/distortion of the workpiece, and how this can be

overcome19. How to recognise spinning faults and identify when forming tools need dressing or sharpening20. The quality control procedures used, inspection checks that need to be carried out, and the equipment that will need

to be used21. The problems that can occur with the metal spinning activities, and how these can be overcome22. The extent of your own authority and whom you should report to when you have problems that you cannot resolve


153





required)evidence typedate checks and practices (all)machine guards adjustedmachine settings adjustedcomponents meet specificationforming/cutting tools in suitable conditionsafe working practicescomponents held securelyproduce components combining different operations (ten)convex shapes concave shapesbulging/necking flangesconescylindersjoints and joininglippinghemispheresre-entranttrimmingdouble seamingbeadingmake components (one)ferrousnon-ferrousproduce components to quality and accuracy standard (all)tolerance to BS4500/BS1916 Grade 9surface finish 63µin or 1.6µmangles/tapers +/- 0.5 degreeshape and form meet template specification requirementfree from ripples, deformity, burrs, sharp edgescarry out checks during production for accuracy (five)external diametersinternal diameterslengthsdepthsanglesprofilessurface finish


Candidate: Date:

Assessor: Date:


154

Unit No 30: Loading and Proving NC/CNC Machine Tool Programs

Unit Summary

This unit identifies the competencies you need to load and prove machine tool programs on Numerically Controlled (NC) or Computer Numerically Controlled (CNC) machine tools, in accordance with approved procedures. You will be required to obtain the correct component program, which may be on punched or magnetic tape, disk or downloaded from a remote computer. You will need to check the program for currency and load it correctly into the machine controller, checking for fault/error messages and dealing with these as appropriate to your level of responsibility. You will also be required to adjust the machine tool equipment and program, following proving/editing procedures, to achieve component specification. You must ensure that any edited programs are saved safely and correctly.

Your responsibilities will require you to comply with organisational policy and procedures for obtaining, loading and proving the programs, and to report any problems with these activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying the machine tool programming procedures used. You will understand the NC/CNC machine tools used in the process, and their application, and will know about the programming, editing and proving process, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the machine controller is set up to produce the components to the required specification.

You will understand the safety precautions required when working on the machine and it’s associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

Setting workholding devices and tooling is the subject of other units.


155

Unit No 30: Loading and Proving NC/CNC Machine Tool ProgramsPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Use the correct control program and ensure it is correctly loaded into the machine controllerc. Follow the correct procedures for calling up the program and dealing with any error messages or faultsd. Confirm program integritye. Adjust the equipment and program operating parameters to optimise the outcomes to be achievedf. Load and correctly set-up all associated equipmentg. Check that all safety mechanisms are in place and that the equipment is set correctly for the required operationsh. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must:1. Ensure that you apply all the following checks and practices during the programming activities:

the correct operating program is obtained and checked for currency and validitythe machine controller is prepared ready to accept the operating programthe program is loaded into the controller safely and correctlyprogram media is stored safely and correctly, away from contaminants or electromagnetic sources

2. Load and prove programs for one of the following types of NC/CNC machine tool:two axis machinethree axis machinemultiple axis machines (5 or more)machining centres

3. Obtain and load programs stored on one of the following mediums:punched tapediskmagnetic taperemote computer system

4. Operate a NC/CNC machine controller using six of the following, as applicable to the machine type:● single block run● graphic displays● full dry run● search facilities● program save/store facilities● edit facilities● program override controls (speed, feed, tool data)● data input facilities

5. Confirm the machine and program operates safely and correctly by checking all of the following, as applicable to the machine type::

• datums for each machine axis are set in relation to all equipment and tooling used• tool offsets are correctly entered into the machine controller● tool change positions are safe and clear of the workpiece and machine equipment● the correct tools are selected at the appropriate points in the program ● tool cutter paths are executed safely and correctly ● all operations are carried out to the program co-ordinates ● any alterations to programs are communicated fully to the appropriate personnel


156

Unit No 30: Loading and Proving NC/CNC Machine Tool ProgramsKnowledge statements:


1. The specific safety precautions to be taken when loading and proving NC/CNC machine tool operating programs2. How to start and stop the machine in normal and emergency situations3. The importance of wearing the appropriate protective clothing and equipment, and of keeping the work area clean

and tidy4. How to handle and store program tapes and disks safely and correctly, away from contaminants and electromagnetic

sources5. The computing coding language used in NC and CNC programs6. The function keys and operating system of the machine computer control system being operated7. How to load, execute, edit and exit programs correctly8. How to set machine datums for each of the machine axis being used9. How to deal with error messages and faults on the program or computer controlled equipment10. How to place the machine into the correct operating mode and access the program edit facility, in order to enter

tooling data such as tool datums, positions, lengths, offsets and radius compensation11. The use of tool posts, magazines and carousels, and how to identify the tools in relationship to the operating

program12. How to conduct trial runs, using single block run, dry run and feed and speed override controls13. The things that you need to check before allowing the machine to operate in full program run mode14. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing16. Factors which will affect the feeds and speeds that can be used, and why they may need to be adjusted from the

program setting (condition of material, workholding method, tooling used, tolerance and finish to be achieved)17. The application of cutting fluids with regard to a range of different materials, and why some materials do not require

the use of cutting fluids18. Typical problems that can occur with the loading and editing of the operating program, and what to do if they occur19. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


157





required)evidence typedate apply checks and practices during programming (all)correct operating programcontroller prepared for operating programprogram loaded correctlyprogram media stored safelyload and prove programs for NC/CNC machine tool (one)two axis machinethree axis machinemultiple axis machine (5 or more)machining centresobtain and load programs stored on (one)punched tapediskmagnetic taperemote computer systemoperate NC/CNC machine controller using (six)single block rungraphic displaysfull dry runsearch facilitiesprogram save/store facilitiesedit facilitiesprogram override controlsdata input facilitiesconfirm machine operates safely and correctly (all as appropriate)datums for each machine axis are settools offsets are correcttool positions are safe/clearcorrect tools selected tool cutters paths executed safely and correctlyall operations carried out to program co-ordinatesany alterations to programs are communicated fully

knowledge and understanding reference:

candidate: Date:

assessor: Date:


158

Unit No 31: Carrying Out CNC Machine Tool Programming

Unit Summary

This unit identifies the competencies you need to produce, load and prove machine tool programs on Computer Numerically Controlled (CNC) machine tools, in accordance with approved procedures. You will be required to produce the component program, using manual data input or by use of a remote computer, saving the prepared program on magnetic tape, disc or by downloading it into the machine controller from the computer. You will need to check the program using single block run and program edit facilities. You will also be required to adjust the machine tool equipment and program, following proving/editing procedures, to achieve component specification. You must ensure that any edited programs are saved safely and correctly.

Your responsibilities will require you to comply with organisational policy and procedures for producing, loading and proving the programs, and to report any problems with these activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying the machine tool programming procedures used. You will understand the CNC machine tools used in the process, and their application, and will know about the programming, editing and proving process, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the machine controller is set up to produce the components to the required specification.

You will understand the safety precautions required when working on the machine and it’s associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

Setting workholding devices and tooling is the subject of other units.


159

Unit No 31: Carrying Out CNC Machine Tool ProgrammingPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Use the correct control program and ensure it is correctly loaded into the machine controllerc. Follow the correct procedures for calling up the program and dealing with any error messages or faultsd. Confirm program integritye. Adjust the equipment and program operating parameters to optimise the outcomes to be achievedf. Load and correctly set-up all associated equipmentg. Check that all safety mechanisms are in place and that the equipment is set correctly for the required operationsh. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must:1. Ensure that you apply all the following checks and practices during the programming activities:

the correct component drawings are obtained and checked for currency and validitythe appropriate reference manuals and programming codes are used to suit the machine controllerthe machine controller is prepared ready to accept the operating programthe prepared program is input/loaded into the controller safely and correctlyprograms are stored safely and correctly in the appropriate formatprogram media is stored safely and correctly, away from contaminants or electromagnetic sources

2. Prepare, load and prove programs for one of the following types of CNC machine tool:two axis machinethree axis machine

multiple axis machines (5 or more)machining centres

3. Produce CNC programs using one of the following methods:written entered directly into the machine controller using computer software

4. Develop part programs which contain all of the following, as applicable to the machine type: all necessary positional informationappropriate letter address codespreparatory commands and machine management/auxiliary functionsrepetitive programs (sub-routines, canned cycles, labels)absolute or incremental systems of measurementtool/cutter change positionstool information (lengths, offsets, radius compensation, wire size)

5. Prove the part program using six of the following:● single block run● graphic displays

● full dry run● search facilities

● program save/store facilities● edit facilities

● program override controls (speed, feed, tool data) ● data input facilities6. Confirm that the machine and program operates safely and correctly, by checking all of the following:

all operations are carried out to the program co-ordinates tool change positions are safe and clear of the workpiece and machine equipmentthe correct tools are selected at the appropriate points in the program tool cutter paths are executed safely and correctly auxiliary functions operate at the correct point in the program (cutter start/stop, coolant flow)programs have been saved in the appropriate format


160

Unit No 31: Carrying Out CNC Machine Tool ProgrammingKnowledge statements:


1. The specific safety precautions to be taken when loading and proving CNC machine tool operating programs2. How to start and stop the machine in normal and emergency situations3. The importance of wearing the appropriate protective clothing and equipment, and of keeping the work area clean

and tidy4. The computer coding language used in CNC programs with regard to machine axes, positional information,

machine management and auxiliary functions5. How to use and extract information from engineering drawings and related specifications, to include symbols and

conventions to appropriate BS or ISO standards in relation to work undertaken6. How to interpret first and third angle drawings, imperial and metric systems of measurement, and system of

tolerancing7. How to interpret CNC drawings, and the use of workpiece zero/reference points8. The systems of measurement used on CNC drawings, including absolute and incremental9. The use of repetitive programs and canned cycles, to reduce program size and input time10. How to prepare part programs, using operational sequences and machining techniques which avoid unnecessary

tool/cutter movements or tool changes11. The function keys and operating system of the machine computer control system being operated12. How to set machine datums for each of the machine axes being used13. How to set the machine controller in the program and editing mode, and enter or download the prepared program14. How to deal with error messages and faults on the program or equipment15. How to access the program edit facility, in order to enter tooling data such as tool datums, positions, lengths,

offsets and radius compensation16. The use of tool posts, magazines and carousels, and how to identify the tools in relationship to the operating

program17. How to conduct trial runs, using single block run, dry run and feed and speed override controls18. Factors which will affect the feeds and speeds that can be used, and why they may need to be adjusted from the

program setting (condition of material, workholding method, tooling used, tolerance and finish to be achieved)19. The things that you need to check before allowing the machine to operate in full program run mode20. How to save the completed programs in the appropriate format, and the need to store program tapes and disks

safely and correctly, away from contaminants and electromagnetic sources21. Typical problems that can occur with the programming, loading and editing activities, and what to do if they occur22. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


161





required)evidence typedate apply checks and practices during programming (all)components drawings obtained and checkedappropriate reference manuals and codes usedcontroller prepared for operating programprogram input/loaded correctlyprogram stored safelyprogram media stored correctlyprepare, load and prove CNC machine tools (one)two axis machinethree axis machinemultiple axis machinemachining centresproduce CNC programs (one)writtendirectly into machine controlleruse computer softwaredevelop part programs (all as applicable)positional informationletter address codespreparatory commandsrepetitive programsabsolute/incremental systems of measurementtool/cutter change positionstool informationprove part program (six)single block rungraphic displaysfull dry runsearch facilitiessave/store facilitiesedit facilitiesprogram override controlsdata inputconfirm machine operates safely and correctly (all)all operations to program co-ordinatestool change positions safe and clear of workpiececorrect tools selected at appropriate pointstool cutter paths safe/correctauxiliary functions operate at correct point in programprograms saved appropriately


Candidate: Date:

Assessor: Date:

Unit No 32: Setting NC/CNC Turning Machines for Production


162

Unit No 32: Setting NC/CNC Turning Machines for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up Numerical Controlled machines (NC), or Computer Numerical Controlled machines (CNC) or Computer Numerical Controlled machining centres, in accordance with approved procedures. You will be expected to select the appropriate workholding devices, and to mount and secure them to the machine spindle. You will also be required to select the appropriate cutting tools, mount and secure them to the appropriate tool holding devices, and place the cutting tools in the relevant positions within the tool posts, turrets, slides or tool change magazine/carousel, where this is applicable.

You will need to ensure that all the tools have been allocated a relevant tool number, and that the relevant data on their co-ordinates and datum positions are entered into the operating program and machine. This will involve loading and proving component programs, checking for errors/faults, editing and saving program changes.

You must produce trial components and prove the machine is working satisfactorily before declaring the machine ready for production. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.

Your responsibilities will require you to comply with organisational policy and procedures for the machine setting activities undertaken, and to report any problems with the equipment, tooling, programs or setting-up activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting-up procedures used. You will understand the CNC turning machine used, and its application, and will know about the workholding devices, tooling, machine operating programmes and setting-up procedures, in adequate depth to provide a sound basis for setting up the equipment, correcting faults, and ensuring the work output is produced to the required specification.



163

Unit No 32: Setting NC/CNC Turning Machines for ProductionPerformance statements:




• confirm the correct operating program has been loaded• check the tooling is in a usable condition• ensure the workpiece is correctly positioned and secured without distortion• update program tool data as applicable• position and adjust machine guards • apply safe working practices at all times

2. Prepare one of the following NC/CNC turning machines in readiness for production:NC lathe CNC lathe ● CNC machining centre

3. Position and secure workpieces using two of the following workholding methods and devices:● chucks with hard jaws ● chucks with soft jaws ● fixtures ● drive centres● collet chucks ● faceplates ● magnetic/pneumatic devices ● other workholding devices

4. Select and mount the appropriate tool holding device and eight of the following types of cutting tool: ● roughing tool● finishing tool● parting-off tool

● screw-thread tool● profiling tools ● form tools

centre drills● twist/core drills● boring tools

● reamers● maxi-tipped drills

5. Prepare the tooling for operation, by carrying out all the following activities, as applicable to the machine type:● positioning tools in the correct position in the tool posts, turrets, magazine or carousel ● checking tools have a specific tool number in relation to the operating program● entering all relevant tool data to the operating program (tool lengths, tool offsets, radius compensation)● pre-setting tooling using setting jigs/fixtures ● setting tool datum ● saving changes to programme

6. Set up the machine to produce components combining several different operations, covering ten from:● parallel diameters• stepped diameters● tapered diameters● flat faces ● internal undercuts● external undercuts

● internal profiles ● external profiles● reamed holes● tapped holes● drilled holes● parting-off

● eccentric diameters● external screw threads● internal screw threads● chamfers and radii● bored holes● grooves

7. Machine one of the following types of material:• ferrous • non-ferrous • stainless • non-metallic

8. Make trial components to prove machine is operating to required specification to include all the following:● dimensional tolerance equivalent to BS4500 or BS 1916 Grade 7● surface finish 63µin or 1.6µm ● reamed and bored holes within H8● angles within +/- 0.5 degree● screw threads BS medium fit


164

Unit No 32: Setting NC/CNC Turning Machines for ProductionKnowledge statements:


1. The specific safety precautions to be taken when setting up workholding devices and tooling on NC/CNC lathes2. How to start and stop the machine in normal and emergency situations3. The importance of ensuring the machine is isolated from the power supply before mounting cutting tools and

workholding devices4. The importance of wearing the appropriate protective clothing and equipment, and of keeping the work area clean and

tidy5. The hazards associated with working on NC/CNC lathes (such as use of power operated chucks, moving machinery,

automatic machine operation, handling cutting tools, lifting and handling workholding devices, hot and airborne metal particles), and how to minimise them

6. How to handle and store cutting tools and verified tapes and programs, safely and correctly7. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing9. The range of workholding methods and devices that are used on NC/CNC lathes10. Why it is important to set the workholding device in relationship to the machine datums and reference points11. The methods of setting the workholding devices, and the tools and equipment that can be used12. The range of cutting tools that are used on NC/CNC lathes, and typical applications13. How to check that the cutting tools are in a safe and serviceable condition14. The use of tungsten carbide, ceramic and diamond indexible tips, and the factors which will determine their selection

and use (the condition of material supplied, hardness of the material, the cutting characteristics of the material, tolerances to be achieved, component surface finish and specifications)

15. The various tool holding devices that are used, and the methods of correctly mounting and securing the cutting tools to the tool holders

16. The advantages of using pre-set tooling, and how to set the tooling using setting jigs/fixtures17. The use of tool posts, magazines and carousels, and how to position and identify the tools in relationship to the

operating program18. How to place the machine into the correct operating mode, and how to access the program edit facility in order to enter

tooling data, such as tool datums, positions, lengths, offsets and radius compensation19. How to conduct trial runs using single block run, dry run and feed and speed override controls20. The things that you need to check before allowing the machine to operate in full program run mode21. How the various types of materials used will affect the feeds and speeds that can be used22. The application of cutting fluids with regard to a range of different materials, and why some materials do not require the

use of cutting fluids23. Typical problems that can occur with the setting up of the tooling and workholding devices, and what to do if they occur24. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


165





required)evidence typedate carry out activities during setting up (all)correct operating programtooling in usable conditionworkpiece correctly positioned and securedupdate tool data as appropriateposition and adjust machine guardssafe working practicesprepare NC/CNC turning machines for production (one)NC latheCNC latheCNC machining centreposition and secure workpieces using (two)hard jaw chuckcollet chucksoft jaw chuckfaceplatesfixturesmagnetic/pneumatic devicesdrive centresother devicesselect and mount tool holding device and cutting tools (eight different tools required)roughing toolfinishing toolparting-off toolscrew thread toolprofiling toolscentre drillstwist/core drillsboring toolsreamersmaxi-tipped drillsform toolsprepare the tooling for operation (all as applicable)position tools correctlycheck tools specific number in relation to programentering relevant tool datausing setting jigs/fixturessetting tool datumsaving changes to program


166





required)evidence typedate set up machine to produce components combining several operations (ten)parallel diametersstepped diameterstapered diametersflat facesinternal undercutsexternal undercutsinternal profilesexternal profilesreamed holestapped holesdrilled holesparting-offeccentric diametersexternal screw threadsinternal screw threadschamfers and radiibored holesgroovesmachine material (one)ferrousnon-ferrousstainlessnon-metallicmake trial components to prove machine operates to required specification (all)tolerance to BS4500/BS1916 Grade 7surface finish 63µin or 1.6µmbored holes within H8angles within +/-0.5 degreescrew threads BS medium fit


Candidate: Date:

Assessor: Date:


167

Unit No 33: Machining Components using NC/CNC Turning Machines

Unit Summary

This unit identifies the competencies you need to carry out turning operations, in accordance with approved procedures, using Numerical Controlled machines (NC), or Computer Numerical Controlled machines (CNC) or Computer Numerical Controlled machining centres. You will take charge of the prepared machine and check that it is ready for the machining operations to be performed. This will involve checking that all the required components and consumables are present, and that the machine has been approved for production. In operating the machine, you will be expected to follow the correct procedures for calling up the operating program, dealing with any error messages, and executing the program activities safely and correctly.

The components produced will have a number of different features, including turned plain diameters, eccentricdiameters, internal/external threads, stepped diameters, flat faces and shoulders, chamfers and radii, special forms and profiles, tapered diameters and faces, internal and external profiles, grooves/undercuts, steps, drilled holes, reamed and tapped holes, and plain and tapered bored holes. You will be required to continuously monitor the machining operations, making any necessary adjustments to machine parameters, in line with your permitted authority. Meeting production targets will be an important issue, and your production records must show consistent and satisfactory performance.

Your responsibilities will require you to comply with organisational policy and procedures for the activities undertaken, and to report any problems with the equipment, tooling, program, materials or activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work to instructions, taking personal responsibility for your own actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will be sufficient to provide a good understanding of your work, and will enable you to adopt an informed approach to applying NC/CNC turning procedures. You will have an understanding of the NC/CNC turning process, and its application, and will know about the machine, tooling, materials, machining activities and consumables, in adequate depth to provide a sound background to the machine operation and for carrying out theactivities to the required specification.


Setting up of the machine, its tooling and associated workholding devices, are the subjects of other units.


168

Unit No 33: Machining Components using NC/CNC Turning MachinesPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Confirm that the equipment is set up and ready for operationc. Follow the defined procedures for starting and running the operating systemd. Deal promptly and effectively with error messages or equipment faults that are within your control and report those

that cannot be solvede. Monitor the computer process and ensure that the production output is to the required specificationf. Shut down the equipment to a safe condition on conclusion of the activities


You must:1. Confirm that the machine is ready for operation by checking all of the following:

• machine guards are in place and correctly adjusted• components are correctly positioned and held securely without distortion• cutting tools are in a suitable condition• the operating program is at the correct start point • the workpiece is clear of the machine spindle• safe working practices and startup procedures are observed• machine settings are adjusted as required to maintain accuracy

2. Operate one of the following NC/CNC turning machines:NC lathe ● CNC lathe ● CNC machining centre

3. Produce components combining several different operations, and covering ten of the following features:parallel diametersstepped diameterstapered diameters

● flat faces ● internal undercuts● external undercuts

● internal profiles ● external profiles● reamed holes● tapped holes● drilled holes● parting-off

● eccentric features● external screw threads● internal screw threads● chamfers and radii● bored holes● grooves

4. Machine one of the following types of material: ferrousnon-ferrousstainlessnon-metallic

5. Produce components within all the relevant quality and accuracy standards: ● dimensional tolerance equivalent to BS4500 or BS 1916 Grade 7● surface finish 63µin or 1.6µm ● reamed and bored holes within H 8● angles within +/- 0.5 degree● screw threads BS medium fit

6. Carry out the necessary checks during production, for accuracy of at least five of the following:● diameters● hole size/fit● angle/taper● surface finish

● lengths/depths● thread profile and fit● concentricity● slot/recess width


169

Unit No 33: Machining Components using NC/CNC Turning MachinesKnowledge statements:


1. The specific safety precautions to be taken when working with NC/CNC turning machines and equipment2. The safety mechanisms on the machine, and the procedures for checking that they are operating correctly3. How to start and stop the machine in both normal and emergency situations4. The hazards associated with working on NC/CNC lathes (such as use of power operated chucks, moving machinery,

automatic machine operation, handling cutting tools, lifting and handling workholding devices, hot and airborne metal particles)


6. The application of a range of NC/CNC turning machines (such as NC or CNC lathes and CNC machining centres)7. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing9. How to interpret the visual display and understand the various messages displayed10. The function of error messages and what to do when an error message is displayed11. How to find the correct restart point in the program when the machine has been stopped before completion of the

program12. The operation of the various hand and automatic modes of machine control (such as hand wheels, joysticks,

program operating and control buttons)13. How to operate the machine using single block run, full program run and feed/speed override controls14. How to make adjustments to the program operating parameters to take account of tool wear15. How to set and secure the workpiece to the machine spindle/workholding device; the effects of clamping the

workpiece; and how material removal can cause warping/distortion of the finished workpiece16. The various types of cutting tools used, and how they are located and secured to the machine tool posts, turrets,

slides and tool magazine or carousel17. The safe and correct handling and storage of tooling18. How to check that the indexible tooling is in a serviceable condition, and the effects that worn tooling will have on

the workpiece surface finish and tolerances19. The problems that can occur with turning activities, and how these can be overcome20. The application of cutting fluids with regard to different materials being machined21. The quality control procedures used, inspection checks that need to be carried out, and the equipment that is used22. Where to obtain component drawings, specifications and/or job instructions required for the components being

machined23. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


170





required)evidence typedate confirm machine is ready for operation by checking (all)machine guards are adjustedcomponents held securelytools in suitable conditionoperating program at correct start pointworkpiece clear of machine spindlemachine settings adjustedoperate NC/CNC turning machines (one)NC latheCNC latheCNC machining centreproduce components combining operations (ten features)parallel diametersstepped diameters tapered diametersflat facesinternal undercutsexternal undercutsinternal profilesexternal profilesreamed holestapped holesdrilled holes parting-offeccentric featuresexternal screw threadsinternal screw threadschamfers and radiibored holesgroovesmachine material (one)ferrousnon-ferrousstainlessnon-metallicproduce components within quality and accuracy standards (all)BS4500/BS1916 Grade 763µin or 1.6µmbored holes within H8angles within +/- 0.5 degreethreads BS medium fit


171





required)evidence typedate carry out checks for accuracy during production (five)diametershole/size/fitangle/tapersurface finishlengths/depthsthread profile and fitconcentricityslot/recess width


Candidate: Date:

Assessor: Date:


172

Unit No 34: Setting NC/CNC Milling Machines for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up Numerical Controlled machines (NC), or Computer Numerical Controlled (CNC) three axis or five axis machines or Computer Numerical Controlled machining centres, in accordance with approved procedures. This involves selecting the appropriate workholding devices, and mounting and positioning them to the machine table in the designated or appropriate position, as required by the machine-operating program. You will also be required to select the appropriate milling cutters to use, and to mount and secure them to the appropriate tool holding devices. You will be expected to place the tools in the relevant positions within the tool change magazine or carousel, where this is applicable.

You will need to ensure that all the tools have been allocated a relevant tool number and that the relevant data on their co-ordinates and datum positions are entered into the operating program and machine. This will involve loading and proving the component program, checking for errors/faults, editing and saving program changes. You must produce trial components and prove the machine is working satisfactorily before declaring the machine ready for production. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.


Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting-up procedures used. You will understand the NC/CNC milling machine used, and its application, and will know about the workholding devices, tooling, materials, machine operating program and setting-up procedures, in adequate depth to provide a sound basis for setting-up the equipment, correcting faults and ensuring the work output is produced to the required specification.



173

Unit No 34: Setting NC/CNC Milling Machines for Production Performance statements:



You must:1. Carry out all the following activities during setting-up:

• confirm the correct operating program has been loaded• check the tooling is in a usable condition• ensure the workpiece is correctly positioned and secured without distortion• update program tool data as applicable• position and adjust machine guards• apply safe working practices at all times

2. Prepare one of the following CNC milling machines in readiness for production:• CNC three axis milling machine • CNC five axis milling machine • CNC machining centre

3. Position and secure workpieces using two of the following workholding methods and devices:● machine vices● fixtures● chucks

● pneumatic or magnetic table● direct clamping to machine table

● ancillary indexing devices● angle plate

4. Select and mount four of the following types of milling cutters to the appropriate tool holding device:● face mills● end mills

● twist/core drills● boring tools

● reamers ● slot drills

● special profile cutters

5. Prepare tooling for operation by carrying out all the following activities, as applicable to the machine type: ● positioning tools in the correct position in the tool magazine or carousel ● checking tools have specific tool number in relation to the operating program● entering all relevant tool data to the operating program (tool lengths, tool offsets, radius compensation) ● presetting tooling using setting jigs/fixtures ● setting tool

datum● saving changes to programme

6. Set up the machine to produce components, combining different operations, covering eight from:● flat faces● steps/shoulders● enclosed slots/recesses● internal profiles

● holes on pitch circles● parallel faces● angular faces● open ended slots

● external profiles● holes linearly pitched● circular/curved profiles

● special forms (such as concave, convex) ● faces that are square to each other7. Machine components made from one of the following types of material:

• ferrous • non-ferrous • stainless ● non-metallic8. Make trial components to prove machine is operating to required specification, to include all the following:

● dimensional tolerance equivalent to BS4500 or BS 1916 Grade 7● surface finish 63µin or 1.6µm ● reamed and bored holes within H8● flat and square 0.001” per inch or 0.025mm per 25mm● angles within +/- 0.5 degree


174

Unit No 34: Setting NC/CNC Milling Machines for Production Knowledge statements:


1. The specific safety precautions to be taken when setting up workholding devices and tooling on CNC milling machines

2. How to start and stop the machine in normal and emergency situations3. The importance of ensuring the machine is isolated from the power supply before mounting cutters and

workholding devices4. The hazards associated with working on NC/CNC milling machines (such as use of power operated workholding

devices, moving machinery, automatic machine operation, handling cutting tools, lifting and handling workholding devices, hot and airborne metal particles), and how to minimise them


6. How to handle and store milling cutters safely and correctly7. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing9. How to read and interpret CNC drawings and extract the relevant information10. The range of workholding methods and devices that are used on CNC milling machines11. Why it is important to set the workholding device in relation to the machine axis and reference points12. The methods of setting the workholding devices, and the tools and equipment that can be used13. The range of cutting tools that are used on CNC milling machines, and typical applications14. The use of tungsten carbide, ceramic and diamond indexible tips, and the factors which will determine their

selection and use (condition of material supplied, hardness of the material, cutting characteristics of the material, tolerances to be achieved, component surface finish and specifications)

15. How to check that the cutting tools are in a safe and serviceable condition16. The various tool holding devices that are used, and the methods of mounting and securing the cutting tools to the

tool holders17. The advantages of using pre-set tooling, and how to set the tooling using setting jigs18. The use of tool magazines and carousels, and how to position and identify the tools in relation to the operating

program19. How to place the machine into the correct operating mode, and how to access the program edit facility in order to

enter tooling data (such as tool lengths, tool offsets, radius compensation)20. How to conduct trial runs using single block run, dry run, and feed and speed override controls21. The things that you need to check before allowing the machine to operate in full program run mode22. How the various types of materials used will affect the feeds and speeds that can be used23. The application of cutting fluids with regard to a range of different materials, and why some materials do not

require the use of cutting fluids24. Typical problems that can occur with the setting up of the tooling and workholding devices, and what to do if they

occur25. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


175





required)evidence typedate carry out activities during setting up (all)correct operating program loadedtooling in usable conditionworkpiece correctly positioned/securedupgrade tool data adjust machine guardssafe working practicesprepare CNC milling machines (one)CNC three axis milling machineCNC five axis milling machineCNC machining centreposition and secure workpiece using workholding methods/devices (two)machine vicesfixtureschuckspneumatic/magnetic tabledirect clamped machine tableancillary indexing devicesangle plateselect & mount milling cutters to appropriate tool holding device (four)face mills end millstwist/core drillsboring toolsreamersslot drillsspecial profile cuttersprepare tooling for operation (all as appropriate)positioning tools correctlychecking tool numbersentering relevant tool datapresetting tooling jigs/fixturessetting tool datumsaving changes to programset up machine to produce components combining different operations (eight)flat facessteps/shouldersenclosed slots/recessesinternal profilesspecial formsholes on pitch circlesparallel facesangular facesopen ended slotsexternal profilesholes linearly pitchedcircular/curved profilesfaces that are square to each other






176

evidence (if required)

evidence typedatemachine components material (one)ferrousnon-ferrousstainlessnon-metallicmake trial components to prove machine operates to required specification (all)BS4500/BS1916 Grade 763µin or 1.6µmReamed and bored holes H80.001”- 0.025mm per 25mmAngles within +/-0.5 degree


Candidate: Date:

Assessor: Date:


177

Unit No 35: Machining Components using NC/CNC Milling Machines

Unit Summary

This unit identifies the competencies you need to operate Numerical Controlled (NC) machines, or Computer Numerical Controlled (CNC) three axis or five axis machines or Computer Numerical Controlled machining centres, in accordance with approved procedures. You will take charge of the prepared machine and check that it is ready for the machining operations to be performed. This will involve checking that all the required components and consumables are present, and that the machine has been approved for production. In operating the machine, you will be expected to follow the correct procedures for calling up the operating program, dealing with any error messages, and executing the program activities safely and correctly.

The components produced will have a number of different features, including such things as flat faces, angled faces, internal and external profiles, slots, steps, holes which are linearly or circularly pitched, and special profiles such as convex or concave. You will be required to continuously monitor the machining operations, making any necessary adjustments to machine parameters, in line with your permitted authority. Meeting production targets will be an important issue, and your production records must show consistent and satisfactory performance.

Your responsibilities will require you to comply with organisational policy and procedures for the activities undertaken, and to report any problems with the machine, tooling, materials or machining activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work to instructions, taking personal responsibility for your own actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will be sufficient to provide a good understanding of your work, and will enable you to adopt an informed approach to applying NC/CNC milling procedures. You will have an understanding of the NC/CNC milling process, and its application, and will know about the equipment, tooling, materials and consumables, in adequate depth to provide a sound background to the machine operation and for carrying out the activities to the required specification.




178

Unit No 35: Machining Components using NC/CNC Milling MachinesPerformance statements:




You must:

1. Confirm that the machine is ready for operation, by checking all of the following:• machine guards are in place and correctly adjusted• components are correctly positioned and held securely without distortion• cutting tools are in a suitable condition• the operating program is at the correct start point • the workpiece is clear of the machine spindle• safe working practices and startup procedures are observed• machine settings are adjusted as required to maintain accuracy

2. Operate one of the following CNC milling machines:• three axis milling machine• multi-axis milling machine• machining centre

3. Produce machined components, which combine different operations and cover eight of the following:● flat faces● steps/shoulders● enclosed slots/recesses● internal profiles

● holes on pitch circles● parallel faces● angular faces● open ended slots

● external profiles● holes linearly pitched● circular/curved profiles● tapped holes

● special forms (such as concave, convex)● faces that are square to each other

4. Machine components made from one of the following types of material:ferrous non-ferrous stainless non-metallic

5. Produce components within all the relevant quality and accuracy standards:● dimensional tolerance equivalent to BS4500 or BS 1916 Grade 7● surface finish 63µin or 1.6µm ● reamed and bored holes within H8● flatness and squareness 0.001” per inch or 0.025mm per 25mm● angles within +/- 0.5 degree

6. Carry out the necessary checks during production, for accuracy of five of the following● dimensions● squareness● hole size/fit● surface finish

● angles● flatness● slots● recesses


179

Unit No 35: Machining Components using NC/CNC Milling MachinesKnowledge statements:


1. The specific safety precautions to be taken when working with CNC milling machines and equipment2. The safety mechanisms on the machine, and the procedures for checking that they are operating correctly3. How to start and stop the machine in both normal and emergency situations4. The hazards associated with working on NC/CNC milling machines (such as use of power operated workholding

devices, moving machinery, automatic machine operation, handling cutting tools, lifting and handling workholding devices, hot and airborne metal particles), and how to minimise them


6. The application of a range of CNC milling machines, such as three axis, five axis and machining centres7. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing9. How to interpret the visual display and understand the various messages displayed10. The function of error messages, and what to do when an error message is displayed11. How to find the correct restart point in the program when the machine has been stopped before completion of the

program12. The operation of the various hand and automatic modes of machine control (such as handwheels, joysticks, program

operating and control buttons)13. How to operate the machine using single block run, full program run, and feed/speed override controls14. How to make adjustments to the program operating parameters to take account of tool wear15. How to set and secure the workpiece to the machine table/workholding device; the effects of clamping the

workpiece; and how material removal can cause warping/distortion of the finished workpiece16. The various types of milling cutters used, and how they are located and secured to the machine spindle, tool

magazine or carousel17. The safe and correct handling and storage of tooling18. How to check that the milling cutters are in a serviceable condition, and the effects that worn cutters will have on the

finished work19. The problems that can occur with the milling activities, and how these can be overcome20. The application of cutting fluids with regard to different materials being machined21. The quality control procedures used, inspection checks that need to be carried out, and the equipment that is used22. Where to obtain component drawings, specifications and/or job instructions required for the components being



180





required)evidence typedate confirm machine is ready for operation by checking (all)machine guards adjustedcomponents are held securelycutting tools in suitable conditionoperating program at start pointworkpiece is clear of spindlesafe working practicesmachine settings adjustedoperate CNC milling machine (one)three axis milling machinemulti-axis milling machinemachining centreproduce machined components combining operations covering (eight)flat facessteps/shouldersenclosed slots/recessesinternal profilesspecial formssquare facesholes on pitch circlesparallel facesangular facesopen ended slotsexternal profilesholes linearly pitchedcircular/curved profilestapped holesmachine components from (one)ferrousnon-ferrousstainlessnon-metallicproduce components within quality and accuracy standards (all)tolerance BS4500/BS1916 Grade 7surface finish 63µin or 1.6µmreamed and bored holes H8flatness/squareness 0.001”-0.025mm per 25mmangles within +/- 0.5 degree


181





required)evidence typedate carry out necessary checks for accuracy during production (five)dimensionssquarenesshole size/fitsurface finishanglesflatnessslots recesses


Candidate: Date:

Assessor: Date:


182

Unit No 36: Setting NC/CNC Grinding Machines for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up Numerically Controlled (NC) or Computer Numerically Controlled (CNC) grinding machines, such as NC universal grinding machines, CNC universal grinding machines, CNC gear grinding machines, CNC ring grinding machines, and CNC grinding machining centre, in accordance with approved procedures. You will be expected to select the appropriate workholding devices, and to mount and secure them to the machine table or spindle in the designated or appropriate position, as required by the machine operating program. You will also be expected to select the appropriate grinding wheels, and to balance, dress, mount and secure them to the appropriate machine spindles and/or tool change magazine/carousel, where this is applicable.

You will need to ensure that all grinding wheels have been allocated a relevant tool number, and that the relevant data on their co-ordinates and datum positions are entered into the operating program and machine controller. This will involve loading and proving component programs, checking for errors/faults, editing and saving program changes. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.

Your responsibilities will require you to comply with organisational policy and procedures for the machine setting activities undertaken, and to report any problems with the equipment, grinding wheels, programs or setting up activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting-up procedures used. You will understand the NC/CNC grinding machine used, and its application, and will know about the workholding devices, grinding wheels, machine operating programs and setting-up procedures, in adequate depth to provide a sound basis for setting up the equipment, correcting faults and ensuring the work output is produced to the required specification.



183

Unit No 36: Setting NC/CNC Grinding Machines for Production Performance statements:




confirm the correct operating program has been loadedcheck the correct grinding wheels are in place, correctly dressed and in a usable conditionensure the workpiece is correctly positioned and secured without distortion

● ensure all the machine safety devices and guards are in positionupdate program tool data as applicable apply safe working practices at all times

2. Prepare one of the following NC/CNC grinding machines in readiness for production:● NC universal grinder ● CNC universal grinder

● CNC gear grinder● CNC grinding machining centre

● CNC thread grinder● CNC ring grinder

3. Position and secure workpieces using four of the following workholding methods and devices:● chucks● collets● clamps

● machine vices● faceplates● vee-blocks

● centers● fixtures● angle plates

● mandrels/arbours● power chucks/blocks● other workholding arrangements

4. Select/mount grinding wheels and dress six of the following types of feature on the grinding wheel:● rough grinding● male radius

● finish grinding● angles

● for thread grinding● component form profile

● for gear grinding● female radius

5. Prepare the tooling by carrying out all of the following activities, as applicable to the machine type: ● pre-setting grinding wheels/spindles using balancing units and setting jigs/fixtures● setting tool datum● positioning grinding wheels/spindles in the correct position in the machine spindle, magazine or carousel ● checking wheels/spindles have a specific tool number in relation to the operating program● entering all relevant tooling data to the operating program (wheel/spindle position offsets)● saving changes to programme

6. Set up to produce ground components, which combine different operations and cover eight of the following: plain diametersstepped diameterstapered diametersflat faces and shoulders

internal and external profileseccentric diametersexternal screw threadschamfers and radii

parallel bores tapered boresinvolute and helical formscurvic couplings

special forms (such as concave, convex) internal/external undercuts/bearing tracks7. Machine one different type of material from :

ferrous non-ferrous stainless non-metallic8. Produce component within all of the following quality and accuracy standards:

● dimensional tolerance equivalent to BS4500 or BS 1916 Grade 7● flat and square 0.0005” per inch or 0.005mm per 25mm● angles within +/- 0.5 degree

● surface finish 32µin or 0.8µm ● ground bores/holes within H8● screw threads BS medium fit


184

Unit No 36: Setting NC/CNC Grinding Machines for Production Knowledge statements:


1. The specific safety precautions to be taken when setting up workholding devices and tooling on NC/CNC grinding machines

2. How to start and stop the machine in normal and emergency situations3. The hazards associated with working on NC/CNC grinding machines (such as moving machinery, automatic machine

operation, sparks/airborne particles, bursting grinding wheels), and how to minimise them4. The Grinding Wheel Regulations covering the use and operation of grinding wheels and equipment5. The importance of ensuring the machine is isolated from the power supply before mounting grinding wheels and


and tidy7. How to handle and store grinding wheels, spindles, verified tapes and programs, safely and correctly8. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing10. The range of workholding methods and devices that are used on NC/CNC grinding machines11. Why it is important to set the workholding device in relation to the machine datums and reference points12. The methods of setting the workholding devices, and the tools and equipment that can be used13. The range of grinding wheels that are used on NC/CNC lathes, and typical applications14. How to check that the grinding wheels are in a safe and serviceable condition15. The use of silicon carbide, aluminium oxide and diamond wheels, and the material conditions determining their use16. Selecting the correct grade and type of grinding wheel for the materials being machined17. The various grinding tool holding devices that are used, and the methods of correctly mounting and securing the

grinding wheels to the machine spindle and tool holders18. The advantages of using pre-set tooling, and how to set the tooling using setting jigs/fixtures19. The use of magazines and carousels, and how to position and identify the tools in relation to the operating program20. How to place the machine into the correct operating mode, and how to access the program edit facility in order to

enter tooling data (such as tool datums, positions, lengths and offsets)21. How to conduct trial runs, using single block run, dry run and feed/speed override controls22. The things that you need to check before allowing the machine to operate in full program run mode23. How the various materials will affect the feeds and speeds that can be used24. The application of cutting fluids with regard to a range of different materials, and why some materials do not require

the use of cutting fluids25. Typical problems that can occur when setting-up of grinding wheels and workholding devices, and what to do if they



185





required)evidence typedate carry out activities during setting up (all)correct operating programcorrect grinding wheelsworkpiece correctly positionedmachine safety devicesupdate program tool datasafe working practicesprepare NC/CNC grinding machines for production (one)NC universal grinderCNC universal grinderCNC gear grinderCNC grinding machine centreCNC thread grinderCNC ring grinderposition and secure workpiece using workholding methods/devices (four)chuckscolletsclampsmachine vicesfaceplatesvee-blockscentersfixturesangle platesmandrels/arbourspower chucks/blocksother workholding arrangementsselect/mount grinding wheels and dress features (six)rough grindingmale radiusfinish grindinganglesthread grindingcomponent form profilegear grindingfemale radiusprepare tooling by carrying out the following activities (all as applicable))pre-setting grinding wheelssetting tool datumpositioning grinding wheelschecking wheels tool numberenter relevant tool datasaving changes to programme


186





required)evidence typedateset up to produce ground components covering (eight)plain diametersstepped diameterstapered diametersflat faces and shouldersspecial formsinternal/external profileseccentric diametersexternal screw threadschamfers and radiiparallel borestapered boresinvolute and helical formscurvic couplingsinternal/external undercuts/bearing tracksmachine material (one)ferrousnon-ferrousstainlessnon-metallicproduce component within quality and accuracy standards (all)tolerance BS4500/BS1916 Grade 70.0005”-0.005mm per 25mmangles within +/- 0.5 degreesurface finish 32µin or 0.8µmground bores/holes within H8screw threads BS med fit


Candidate: Date:

Assessor: Date:


187

Unit No 37: Machining Components using NC/CNC Grinding Machines

Unit Summary

This unit identifies the competencies you need to carry out grinding operations, in accordance with approved procedures, using Numerically Controlled (NC) machines or Computer Numerically Controlled (CNC) machines, such as universal grinding machines, gear grinding machines, thread grinding machines, ring grinding machines and grinding machining centres. You will take charge of the prepared machine and check that it is ready for the grinding operations to be performed. This will involve checking that all the required components and consumables are present, and that the machine has been approved for production. In operating the machine, you will be expected to follow the correct procedures for calling up the operating program, dealing with any error messages, and executing the program activities safely and correctly.

The components produced will have a number of different features, including ground plain diameters, eccentric diameters, external threads, stepped diameters, flat faces and shoulders, chamfers and radii, special forms and profiles, tapered diameters and faces, internal and external profiles, grooves/undercuts, gear teeth, bearing tracks, parallel and tapered bores and curvic couplings. You will be required to continuously monitor the machining operations, making any necessary adjustments to machine parameters, in line with your permitted authority. Meeting production targets will be an important issue, and your production records must show consistent and satisfactory performance.

Your responsibilities will require you to comply with organisational policy and procedures for the activities undertaken, and to report any problems with the equipment, tooling, program, materials or activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will be sufficient to provide a good understanding of your work, and will enable you to adopt an informed approach to applying NC/CNC grinding procedures. You will have an understanding of the NC/CNC grinding process, and its application, and will know about the machine, grinding wheels, materials, consumables and grinding activities, in adequate depth to provide a sound background to machine operation and for carrying out the activities to the required specification.


Setting up the machine, its tooling and associated workholding devices, are the subjects of other units.


188

Unit No 37: Machining Components using NC/CNC Grinding MachinesPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Confirm that the equipment is set up and ready for operationc. Follow the defined procedures for starting and running the operating systemd. Deal promptly and effectively with error messages or equipment faults that are within your control and report those that cannot be solvede. Monitor the computer process and ensure that the production output is to the required specificationf. Shut down the equipment to a safe condition on conclusion of the activities


You must: 1. Confirm that the machine is ready for operation by checking all of the following:

• machine guards are in place and correctly adjusted• components are correctly positioned and held securely without distortion• the correct grinding wheels are in place, correctly dressed and in a usable condition• the operating program is at the correct start point • the workpiece is clear of the machine spindle• safe working practices and startup procedures are observed• machine settings are adjusted as required to maintain accuracy

2. Operate one of the following NC/CNC grinding machines: ● NC universal grinder ● CNC universal grinder ● CNC gear grinder

● CNC grinding machining centre● CNC thread grinder● CNC ring grinder

3. Produce ground components, which combine different operations and cover eight of the following:plain diametersstepped diameterstapered diametersflat faces and shoulders

internal and external profileseccentric diametersexternal screw threadschamfers and radii

parallel bores tapered boresinvolute and helical formscurvic couplings

special forms (such as concave, convex) internal/external undercuts/bearing tracks4. Machine one different type of material from:

ferrous non-ferrous

stainless non-metallic

5. Produce component within all of the following quality and accuracy standards:● dimensional tolerance equivalent to BS4500 or BS 1916 Grade 7● flatness and squareness 0.0005” per inch or 0.012mm per 25mm● angles within +/- 0.5 degree● surface finish 32µin or 0.8µm ● ground bores/holes within H8● screw threads BS medium fit

6. Carry out the necessary checks for accuracy during production of at least four of the following: ● dimensions● parallelism● squareness● profile● concentricity

● thread form● surface texture● angle/taper● ovality/lobbing● hole size


189

Unit No 37: Machining Components using NC/CNC Grinding MachinesKnowledge statements:


1. The specific safety precautions to be taken when working with NC/CNC grinding machines and equipment2. The safety mechanisms on the machine, and the procedures for checking that they are operating correctly3. How to start and stop the machine in both normal and emergency situations4. The hazards associated with working on NC/CNC grinding machines (such as moving machinery, automatic

machine operation, sparks/airborne particles, bursting grinding wheels), and how to minimise them5. The Grinding Wheel Regulations covering the use and operation of grinding wheels and equipment6. The importance of wearing the appropriate protective clothing and equipment, and of keeping the work area clean

and tidy7. The application of a range of NC/CNC grinding machines8. How to use and extract information from engineering drawings and related specifications, to include symbols and




program operating and control buttons)14. How to operate the machine using single block run, full program run and feed/speed override controls15. How to make adjustments to the program operating parameters to take account of wheel wear16. How to set and secure the workpiece to the machine table/workholding device; the effects of clamping the

workpiece; and how material removal can cause warping/distortion of the finished workpiece17. The various types of grinding wheels used, and how they are located and secured to the machine spindle, tool

holders and tool magazine or carousel18. The safe and correct handling and storage of grinding wheels19. How to check that the grinding wheel is in a serviceable condition, and the effects that worn/burnished tooling will

have on the workpiece surface finish and tolerances20. The problems that can occur with grinding activities, and how these can be overcome21. The application of cutting fluids with regard to different materials being machined22. The quality control procedures used, inspection checks that need to be carried out, and the equipment that is used23. Where to obtain component drawings, specifications and/or job instructions required for the components being



190





required)evidence typedate confirm machine is ready for operation (all)machine guards adjustedcomponents are held securelycorrect grinding wheels in place & dressedoperating program at correct start pointworkpiece is clear of spindlesafe working practicesmachine settings adjustedoperate NC/CNC grinding machine (one)NC universal grinderCNC universal grinderCNC gear grinderCNC grinding machining centreCNC thread grinderCNC ring grinderproduce ground components combining different operations (eight)plain diametersstepped diameterstapered diametersflat faces and shouldersspecial formsinternal/external profileseccentric diametersexternal screw threadschamfers and radiiparallel borestapered boresinvolute and helical formscurvic couplingsinternal/external undercuts/bearing tracksmachine material (one)ferrousnon-ferrousstainlessnon-metallicproduce components within quality and accuracy standards (all)tolerance to BS4500/BS1916 Grade 7flatness/squareness 0.005” per inch or 0.012mm per 25mmangles within +/- 0.5 degreesurface finish 32µin or 0.8µmground bores/holes within H8screw threads BS med fit


191





required)evidence typedatecarry out necessary checks during production (four)dimensionsparallelismsquarenessprofileconcentricitythread formsurface textureangle/taperovality/lobbinghole size


Candidate: Date:

Assessor: Date:


192

Unit No 38: Setting NC/CNC Punching Machines for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up Numerical Controlled (NC), or Computer Numerical Controlled (CNC) punching machines, in accordance with approved procedures. You will be expected to select the appropriate workholding devices, and to mount and secure them to the machine spindle. You will also be required to select the appropriate cutting tools, mount and secure them to the appropriate tool holding devices, and place the cutting tools in the relevant positions within the tool posts, turrets, slides or tool change magazine/carousel, where this is applicable.

You will need to ensure that all the tools have been allocated a relevant tool number and that the relevant data on their co-ordinates and datum positions are entered into the operating program and machine. This will involve loading and proving component programs, checking for errors/faults, editing and saving program changes. You must produce trial components and prove the machine is working satisfactorily before declaring the machine ready for production. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.

Your responsibilities will require you to comply with organisational policy and procedures for the machine setting activities undertaken, and to report any problems with the equipment, tooling, programs or setting up activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting-up procedures used. You will understand the NC/CNC punching machine used, and its application, and will know about the workholding devices, tooling, machine operating programs and setting-up procedures, in adequate depth to provide a sound basis for setting up the equipment, correcting faults and ensuring the work output is produced to the required specification.



193

Unit No 38: Setting NC/CNC Punching Machines for ProductionPerformance statements:





2. Prepare one of the following NC/CNC punching machines in readiness for production:• NC punching machine • CNC punching machine

3. Position and secure workpieces using two of the following workholding methods and devices:● direct clamping to machine table● magnetic chucks

● pneumatic chucks ● jigs and fixtures

● other workholding devices

4. Select and mount, in the appropriate holding device, two of the following types of punching/forming tool: ● hole punching tools ● nibbling tools ● forming tools

5. Prepare the tooling by carrying out all of the following activities, as applicable to the machine type:● pre-setting tooling using setting jigs/fixtures● setting tool datums● positioning tools in the correct position in the tool posts, turrets, magazine or carousel ● checking tools have a specific tool number in relation to the operating program● entering all relevant tool data to the operating program (tool lengths, tool offsets, radius compensation)● saving changes to program

6. Set up the machine to produce components, combining several different operations, and cover four from: ● holes linearly pitched● holes radially pitched● square/rectangular profiles● curved profiles

● swages● louvres● other applications

7. Machine one of the following types of material: ferrousnon-ferrousstainlessspecial alloys

8. Make trial components to prove machine is operating to required specification, to include all the following: dimensional tolerance equivalent to BS 4500 or BS 1916 Grade 9components to be free from deformity, burrs and sharp edges


194

Unit No 38: Setting NC/CNC Punching Machines for ProductionKnowledge statements:


1. The specific safety precautions to be taken when setting up workholding devices and tooling on NC/CNC punching machines

2. How to start and stop the machine in normal and emergency situations3. The importance of ensuring the machine is isolated from the power supply before mounting punching tools and


and tidy5. The hazards associated with working on NC/CNC punching machines (such as moving machinery, automatic

machine operation, handling punching tools, lifting and handling workholding devices, handling sheet materials) and how to minimise them

6. How to handle and store punching tools and verified tapes and programs, safely and correctly7. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing9. The range of workholding methods and devices that are used on NC/CNC punching machines10. Why it is important to set the workholding device/workpiece in relationship to the machine datums and reference

points11. The methods of setting the workholding devices/workpieces, and the tools and equipment that can be used12. The range of punching tools that are used on NC/CNC punching machines, and typical applications13. How to check that the punching tools are in a safe and serviceable condition14. The use of high-speed steel and tungsten carbide tooling, and the factors which will determine their selection and

use (condition of material supplied, hardness of the material, cutting characteristics of the material, tolerances to be achieved, component surface finish and specifications)

15. The various tool holding devices that are used, and the methods of correctly mounting and securing the punching tools to the tool holders

16. The advantages of using pre-set tooling, and how to set the tooling using setting jigs/fixtures17. The use of tool posts, magazines and carousels, and how to position and identify the tools in relation to the

operating program18. How to place the machine into the correct operating mode, and how to access the program edit facility in order to

enter tooling data (such as tool datums, positions, lengths, offsets and radius compensation)19. How to conduct trial runs using single block run, dry run and feed/speed override controls20. The things that you need to check before allowing the machine to operate in full program run mode21. How the various types of materials will affect the feeds and speeds that can be used22. Typical problems that can occur with the setting up of the tooling and workholding devices, and what to do if they



195





required)evidence typedate carry out activities during setting up (all)correct operating programcheck the tooling conditionworkpiece is correctly positionedupgrade program tool dataadjust machine guardssafe working practicesprepare NC/CNC punching machines (one)NC punching machineCNC punching machineposition and secure workpiece using workholding methods and devices (two)clamping to machine tablemagnetic chuckspneumatic chucksjigs and fixturesworkholding devicesmount in holding device punching/forming tools (two)hole punching tools nibbling toolsforming toolsprepare tooling as applicable to the machine type (all)pre-setting tooling using jigs/fixturessetting tool datumscorrectly positioning toolschecking tools have a specific numberentering relevant tool datasaving changes to programset up machine to produce components (four)holes linearly pitchedholes radially pitchedsquare/rectangular profilescurved profilesswageslouvresother applicationsmachine types of material (one)ferrousnon-ferrousstainlessspecial alloysmake trial components to prove machine is operating to required specification (all)tolerance to BS4500/BS1916 Grade 9free from deformity, burrs and sharp edges


Candidate: Date:

Assessor: Date:


196

Unit No 39: Machining Components using NC/CNC Punching Machines

Unit Summary

This unit identifies the competencies you need to carry out pressing and punching operations, in accordance with approved procedures, using Numerical Controlled (NC) machines, or Computer Numerical Controlled (CNC) machines. You will take charge of the prepared machine and check that it is ready for the machining operations to be performed. This will involve checking that all the required materials and consumables are present, and that the machine has been approved for production. In operating the machine, you will be expected to follow the correct procedures for calling up the operating program, dealing with any error messages, and executing the program activities safely and correctly.

The components produced will have a number of different features, including holes linearly pitched, holes radially pitched, internal square/rectangular profiles, curved/circular profiles, swages, louvres, special forms and profiles. You will be required to continuously monitor the punching operations, making any necessary adjustments to machine parameters, in line with your permitted authority. Meeting production targets will be an important issue, and your production records must show consistent and satisfactory performance.


Your underpinning knowledge will be sufficient to provide a good understanding of your work, and will enable you to adopt an informed approach to applying NC/CNC punching procedures. You will have an understanding of the NC/CNC punching process, and its application, and will know about the machine, tooling, materials, machining activities and consumables, in adequate depth to provide a sound background to the machine operation and for carrying out the activities to the required specification.




197

Unit No 39: Machining Components using NC/CNC Punching MachinesPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Confirm that the equipment is set up and ready for operationc. Follow the defined procedures for starting and running the operating systemd. Deal promptly and effectively with error messages or equipment faults that are within your control and report

those that cannot be solvede. Monitor the computer process and ensure that the production output is to the required specificationf. Shut down the equipment to a safe condition on conclusion of the activities


You must:1. Confirm that the machine is ready for operation, by checking all of the following:

• machine guards are in place and correctly adjusted• components are correctly positioned and held securely without distortion• punching tools are in a suitable condition• the operating program is at the correct start point • the tooling is clear of the workpiece• safe working practices are observed• machine settings are adjusted as required to maintain accuracy

2. Operate one of the following NC/CNC punching machines:• NC punching machine• CNC punching machine

3. Produce components which combine several different operations and cover five of the following: holes linearly pitchedholes radially pitchedinternal curved profilesinternal square profiles

louvresswages other applications

4. Machine one of the following types of material:ferrousnon-ferrousstainlessspecial alloys

5. Produce components within all of the following quality and accuracy standards:dimensional tolerance equivalent to BS 4500 or BS 1916 Grade 9components to be free from deformity, burrs and sharp edges

6. Carry out the necessary checks during production, for accuracy of four of the following:dimensions of punched featuresposition of featureshole positions linearly pitchedhole positions radially pitched

accuracy of profilesflatness / freedom from excessive distortionaccuracy of louvers and swages


198

Unit No 39: Machining Components using NC/CNC Punching MachinesKnowledge statements:


1. The specific safety precautions to be taken when working with NC/CNC punching machines and equipment2. The safety mechanisms on the machine, and the procedures for checking that they are operating correctly3. The hazards associated with working on NC/CNC punching machines (such as moving machinery, automatic

machine operation, handling punching tools, lifting and handling workholding devices, handling sheet materials), and how to minimise them

4. How to start and stop the machine in both normal and emergency situations5. The importance of wearing the appropriate protective clothing and equipment, and of keeping the work area clean

and tidy6. The application of the NC/CNC machine, and the range of operations it can perform7. How to use and extract information from engineering drawings and related specifications, to include symbols and




program operating and control buttons)13. How to operate the machine using single block run, full program run and feed/speed override controls14. How to make adjustments to the program operating parameters, to take account of tool wear15. How to set and secure the workpiece to the machine; the effects of clamping the workpiece; and how material

removal can cause warping/distortion of the finished workpiece16. The various types of punching tools used, and how they are located and secured to the machine tool posts, turrets,

slides and tool magazine or carousel17. The safe and correct handling and storage of tooling18. How to check that the punches are in a serviceable condition, and the effects that worn tooling will have on the

workpiece and tolerances19. The problems that can occur with punching activities, and how these can be overcome20. The quality control procedures used, inspection checks that need to be carried out, and the equipment that is used21. Where to obtain component drawings, specifications and/or job instructions required for the components being



199





required)evidence typedate confirm machine is ready for operation (all)machine guards adjustedcomponents are held securelypunching tools in suitable conditionoperating program at correct start pointtooling is clear of workpiecesafe working practicesmachine settings adjustedoperate NC/CNC punching machine (one)NC punching machineCNC punching machineproduce components which combine operations (five)holes linearly pitchedholes radially pitchedinternal curved profilesinternal square profileslouvresswagesother applicationsmachine material (one)ferrousnon-ferrousstainlessspecial alloysproduce components within quality and accuracy standards (all)tolerance to BS4500/BS1916 Grade 9free from deformity, burrs and sharp edgescarry out checks during production (four)dimensions of punched featuresposition of featureshole positions linearly pitchedhole positions radially pitchedaccuracy of profilesflatness/freedom from excessive distortionaccuracy of louvers/swages


Candidate: Date:

Assessor: Date:


200

Unit No 40: Setting NC/CNC Laser Profiling Machines for Production

Unit Summary

This unit identifies the competencies you need to set up NC/CNC laser profiling machines and associated equipment, in accordance with approved procedures. You will be required to select the appropriate workholding devices, and to mount and secure them to the machine table in the correct relation to the operating program and machine parameters. You will need to set up the machine conditions and adjust/edit program parameters, controlling the setting of the optical system, laser characteristics, laser alignment, electrical parameters, and the laser cutting speed. This will involve loading and proving component programmes, checking for errors/faults, editing and saving program changes.You must produce trial components, and prove the machine is working correctly and producing the components to the required specification, before declaring the machine ready for production. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.

Your responsibilities will require you to comply with organisational policy and procedures for the machine setting activities undertaken, and to report any problems with the equipment or setting activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting up procedures used. You will understand the CNC laser profiling machine used, and its application, and will know about the workholding devices, machine operating programmes and setting-up procedures, in adequate depth to provide a sound basis for setting-up the equipment, correcting faults and ensuring the work output is produced to the required specification.

You will understand the safety precautions required when working on the machine and its associated equipment.You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.


201

Unit No 40: Setting NC/CNC Laser Profiling Machines for ProductionPerformance statements:




• confirm the correct operating program has been loaded• check the tooling is in a usable condition• ensure the workpiece is correctly positioned and secured, without distortion• update program tool data as applicable• position and adjust machine guards• apply safe working practices at all times

2. Position and secure workpieces using three of the following workholding devices:• machine vices• chucks• fixtures

• direct clamping to machine table• Indexing tables/devices• other

3. Set up, in accordance with work instructions and specifications, all of the following:● optical system● laser positioning● profiling parameters

● saving changes to programme● laser alignment● cutting speed

4. Set up the equipment to produce machined components which cover six of the following features:● square/rectangular profiles● angular profiles● curved profiles● circles● ellipses

● holes linearly positioned● holes radially positioned● slots and apertures● other features

5. Machine one of the following types of material: ● ferrous● non-ferrous● stainless/alloy steel● non-metallic

6. Make trial components to prove machine is operating to required specification, to include all the following: ● dimensional tolerance equivalent to BS4500 or BS 1916 Grade 7● angles within +/- 0.5 degree● surface texture within 63µin or 1.6µm


202

Unit No 40: Setting NC/CNC Laser Profiling Machines for ProductionKnowledge statements:


1. The safe working practices and procedures to be observed when setting and operating CNC laser profiling machines (care when working with high power laser beams machine guards; ventilation and fume extraction; machine safety devices)

2. How to start and stop the machine in normal and emergency situations, and how to close the machine down on completion of activities

3. The importance of ensuring the machine is isolated from the power supply before working with machinery; and of taking particular care when working with high-power laser beams


5. The hazards associated with laser machines (dangers from high power laser beams; live electrical components; moving parts of machinery), and how they can be minimised

6. The basic principles of laser profiling (using a laser beam to cut metals; forming component profile; process principles; nature of the laser beam; methods of generating a laser beam; guiding and optical focussing laser optics; parameters; how variation in the parameters influences the component feature, quality and output; terminology used in laser machining)

7. The key components and features of the equipment (types of laser beam generator, beam characteristics, power ranges; beam guiding and focusing arrangements; power sources; materials and thickness capabilities; facilities for manipulating the components for machining; and safety features)

8. How to use and extract information from engineering drawings and related specifications, to include symbols and conventions to appropriate BS or ISO standards in relation to work undertaken

9. How to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing

10. The range of workholding methods and devices used on laser profiling machines11. Methods of setting up the components in relation to the machine’s datums and operating parameters (to achieve

correct laser alignment; manipulation of work holding equipment to present the component correctly relative to the laser).

12. Setting up the laser equipment to achieve the component specification (electrical and optical conditions; focal distance; cutting speed)

13. How to place the machine in the correct operating mode, and how to access the program edit facility in order to make minor adjustments for production

14. How to conduct trial runs, using single block run, speed override controls, and checking that the machine functions to the required specification

15. How the various materials will affect the operating conditions used, and the cutting speed that can be applied16. Problems that can occur with laser cutting activities, and how these can be overcome (causes of distortion and

methods of control, cutting characteristics of parent materials; sources of component defects and methods of prevention)

17. Organisational quality systems (standards to be achieved; production records to be kept)18. The extent of your responsibility and whom you should report to if you have problems that you cannot resolve


203





required)evidence typedate carry out activities during setting up (all)correct operating program loadedtooling is in usable conditionworkpiece correctly positioned/securedupdate program tool dataadjust machine guardssafe working practicessecure workpiece using workholding devices (three)machine viceschucks fixturesclamping to machine tableindexing tables/deviceotherset up according to work instructions and specifications (all)optical systemlaser positioning profiling parameterssaving changes to programmelaser alignmentcutting speedset equipment to produce machined components covering features (six)square/rectangular profilesangular profilescurved profilescirclesellipsesholes linearly positionedholes radially positionedslots and aperturesother featuresmachine material (one)ferrousnon-ferrousstainless/alloy steelnon-metallicmake trial components to prove machine is operating to required specification (all)tolerance to BS4500/BS1916 Grade 7angles within +/- 0.5 degreesurface texture within 63µin or 1.6µm


Candidate: Date:

Assessor: Date:


204

Unit No 41: Machining Components using NC/CNC Laser Profiling Machines

Unit Summary

This unit identifies the competencies you need to carry out cutting and profiling operations using NC/CNC laser profiling machines, in accordance with approved procedures. You will take charge of the prepared machine and check that it is ready for the machining operations to be performed. This will involve checking that all the required materials and consumables are present, and that the machine has been approved for the production. In operating the machine, you will be expected to follow the correct procedures for calling up the machine-operating program, dealing with any error messages, and executing the program activities safely and correctly.

The components produced will have a number of different features, including square and rectangular profiles, angular profiles, curved profiles, circles, holes linearly positioned, holes radially positioned, slots and grooves. You will be required to continuously monitor the machining operations, making any necessary adjustments to machine parameters, in line with your permitted authority. Meeting production targets will be an important issue, and your production records must show consistent and satisfactory performance.

Your responsibilities will require you to comply with organisational policy and procedures for the activities undertaken, and to report any problems with the equipment, program or materials that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying CNC laser profiling procedures. You will understand the CNC profiling process, and its application, and will know about the equipment, materials and consumables, in adequate depth to provide a sound basis for carrying out the activities to the required specification.

You will understand the safety precautions required when working with the laser profiling machine and its associated equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

Setting up the machine, its tooling, workholding devices and associated equipment, are the subjects of other units.


205

Unit No 41: Machining Components using NC/CNC Laser Profiling MachinesPerformance statements:



You must:1. Confirm that the installation is ready for operation, to include checking all of the following:

● the machine has been approved for production● all safety equipment and guards are in place and functioning correctly ● components are correctly positioned and held securely without distortion● the laser lens is clean and in a suitable condition● the operating program is at the correct start point ● the workpiece is clear of the machine spindle● safe working practices and startup procedures are observed● machine settings are adjusted as required to maintain accuracy

2. Produce machined components which cover six of the following features:● square/rectangular profiles● angular profiles● curved profiles● circles● ellipses

● holes linearly positioned● holes radially positioned● slots and apertures● other features

3. Machine one of the following types of material:● ferrous● non-ferrous● stainless/alloy steel● non-metallic

4. Produce components within all of the following quality and accuracy standards:● dimensional tolerance equivalent to BS4500 or BS 1916 Grade 7● angles within +/- 0.5 degree● surface texture within 63µin or 1.6µm

5. Carry out the necessary checks during production for accuracy of four of the following:● dimensions● position of features● holes positioned linearly● holes positioned radially

● angles● profiles● ftatness / freedom from distortion


206

Unit No 41: Machining Components using NC/CNC Laser Profiling MachinesKnowledge statements:


1. The safe working practices and procedures to be observed when setting and operating CNC laser profiling machines (care when working with high power laser beams; machine guards; ventilation and fume extraction; machine safety devices)

2. How to start and stop the machine in normal and emergency situations, and how to close the machine down on completion of activities

3. The importance of ensuring the machine is isolated from the power supply before working with machinery; and the care needed, particularly when working with high power laser beams


5. The hazards associated with laser profiling machines (dangers from the high power laser beam; live electrical components; moving parts of machinery), and how they can be minimised

6. Principles and operation of lasers; laser machines; terminology used7. The key components and features of the equipment (types of laser beam generators, laser characteristics, power

ranges; beam guiding and focussing arrangements; power sources; materials and thickness capabilities; and safety features)

8. How to use and extract information from engineering drawings and related specifications, to include symbols and conventions to appropriate BS or ISO standards in relation to work undertaken

9. How to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing

10. How to interpret the visual display and understand the various messages displayed11. The function of error messages, and what to do when an error message is displayed12. How to find the correct restart point in the program when the machine has been stopped before completion of the


program operating and control buttons)14. How to operate the machine using single block run, full program run and speed override controls15. How to make adjustments to machine operating programs to take account of out-of-specification components16. How to set and secure the workpiece to the work holding device; the effects of clamping the workpiece; and how

material removal can cause distortion in the finished component17. Extracting information required from drawings and component specifications18. Care of equipment and operating programs, including safe storage of material away from electromagnetic forces19. Monitoring the machine during the cutting process; recognition of problems and action to be taken20. Problems that can occur during the laser cutting activities, and how to prevent them21. Organisational quality systems (standards to be achieved; production records to be kept)22. The extent of your responsibility and whom you should report to when you have problems you cannot resolve


207





required)evidence typedate confirm installation is ready by checking (all)machine approved for operationsafety equipment/guardscomponents correctly positioned & held securely laser lens is clean operating program is at correct start pointworkpiece is clearsafe working practices & startup procedures machine settings are adjustedproduce machined components (six)square/rectangular profilesangular profilescurved profilescirclesellipsesholes linearly positionedholes radically positioned slots and aperturesother featuresmachine material (one)ferrousnon-ferrousstainless/alloy steelnon-metallicproduce components to standards (all)dimensional tolerance equivalent to BS4500 or BS1916 grade 7angles within +/- 0.5 degreesurface texture within 63µin or 1.6µmapply checks during production (four)dimensionsposition of featuresholes positioned linearly holes positioned radiallyanglesprofilesother features


Candidate: Date:

Assessor: Date:


208

Unit No 42: Setting NC/CNC Electro Discharge Machines for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up Numerically Controlled (NC) or Computer Numerically Controlled (CNC) electrical discharge machines, such as spark erosion and wire erosion machines, in accordance with approved procedures. You will be expected to select the appropriate workholding devices, and to mount and secure them to the machine table in the designated or appropriate position, as required by the machine-operating program. You will also be expected to select the appropriate electrode cartridge holders or wires, and to mount and secure these to the appropriate machine head/slide and/or tool change holder mechanism, where this is applicable.

You will need to ensure that all electrode cartridges/holders and/or wires have been allocated a relevant tool number, and that the relevant data on their co-ordinates and datum positions are entered into the operating program of the machine. This will involve loading and proving component programmes, checking for errors/faults, editing and saving program changes. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.

Your responsibilities will require you to comply with organisational policy and procedures for the machine setting activities undertaken, and to report any problems with the equipment, tooling programs or setting-up activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting-up procedures used. You will understand the NC/CNC electrical discharge machine used, and its application, and will know about the workholding devices, tooling, machine operating programs and setting-up procedures, in adequate depth to provide a sound basis for setting-up the equipment, correcting faults and ensuring the work output is produced to the required specification.

You will understand the safety precautions required when working with the NC/CNC electro discharge machine and its associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.


209

Unit No 42: Setting NC/CNC Electro Discharge Machines for ProductionPerformance statements:


Scope of the unit:The numbers of scope items specified (below) indicate the minimum requirements for this Occupational Standard.You must:1. Carry out all the following activities during setting-up:

• confirm the correct operating program has been loaded• check the electrode or wire is of the correct type and in a usable condition• check the dielectric fluid is at an appropriate level • check safety devices and guards are in place• position and secure the workpiece without distortion • apply safe working practices at all times

2. Prepare one of the following electro discharge machines for operation:• NC spark or wire erosion machine• CNC spark or wire erosion machine

● CNC electrical discharge machining centre

3. Position and secure workpieces using three of the following workholding methods and devices:● clamping direct to machine table● pneumatic or magnetic table • machine vice (plain, swivel, universal)


● chucks (eg, 3 jaw, 4 jaw)● ancillary indexing device

4. Select, load and set in the appropriate tool holding device, one of the following electrode types:● plain electrodes ● profile electrodes ● hollow electrodes ● wires

5. Prepare the tooling by carrying out all the following activities, as applicable to the machine type:● pre-setting electrodes in tooling cartridges/holders manually or by using setting jigs/fixtures● loading and threading wire through wire feed mechanism and wire guides● positioning electrode cartridges/holders in correct position on machine head or magazine/docking station ● checking electrode cartridges/holders/wire have a specific tool number or technology setting in relation to the

operating program● entering all wire data to the operating program (wire type and size, material thickness, number of skims)● entering all relevant tooling data to the operating program (cartridge/holder position offsets)● setting tool/wire datum point ● saving changes to programme

6. Set up to produce machined components, which combine different operations and cover ten of the from:● flat faces ● parallel faces ● tapered faces ● angular faces● open ended slots/recesses● internal profiles● external profiles

● faces square to each other● enclosed slots/recesses● tapered holes

● holes on pitch circles ● linear holes (rows, angles)● special profiles (eg, concave, convex)

● parallel and tapered steps/slots/shoulders● circular/curved profiles (internal and external)

● other special forms or activities

7. Machine components made from one of the following types of material:• ferrous • non-ferrous

8 . Make trial components to prove the machine is operating to required specification, to include all the following:● dimensional tolerance equivalent to BS4500 or BS 1916 Grade 7● flatness and squareness 0.001” per inch or 0.025mm per 25mm● components to be free from false starts and sharp edges

● surface finish 32µin/0.8µm, 18VDI● machined holes within H8● angles within +/- 0.5 degree


210

Unit No 42: Setting NC/CNC Electro Discharge Machines for ProductionKnowledge statements:


1. The specific safety precautions to be taken when setting up workholding devices and tooling on NC/CNC electrical discharge machinery

2. How to start and stop the machine in normal and emergency situations3. The importance of ensuring the machine is isolated from the power supply before mounting electrodes,

cartridges/holders and workholding devices4. The importance of wearing the appropriate protective clothing and equipment, and of keeping the work area clean

and tidy5. The hazards associated with NC/CNC electro discharge operations (moving parts of machinery, electrical

components, handling dielectrics, fumes), and how they can be minimised6. How to handle and store electrodes or wire, electrode cartridges/holders, verified tapes and programs, safely and

correctly7. How to use and extract information from engineering drawings or other data supplied and related specifications, to

include symbols and conventions to appropriate BS or ISO standards in relation to work undertaken8. How to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference

points and system of tolerancing9. The range of work holding methods and devices that are used on NC/CNC electrical discharge machines10. Why it is important to set the workholding device in relation to the machine datums and reference points11. The methods of setting the workholding devices, and the tools and equipment that can be used12. The range of eroded features that are produced on NC/CNC electrical discharge machines13. How to check that the electrodes or wires are in a good and serviceable condition14. The different types of electrodes/wire, and the material conditions determining their use15. Selecting the correct grade and type of electrode/wire for the materials and profiles being machined16. The various electrode tool holding devices that are used, and the methods of correctly loading, securing and setting

the electrodes/wire in the electrode cartridge/holder/feed mechanism and the machine head/wire guides17. The use of tooling magazines or technology settings, and how to position and identify the tools in relation to the

operating program18. How to place the machine into the correct operating mode, and how to access the program edit facility, in order to

enter tooling data (such as tool datums, positions, height, lengths and offsets, and number of skims)19. How to conduct trial runs using single block run, dry run and feed/speed override controls20. Typical faults that occur when electrical discharge machining and die sinking21. The things that you need to check before allowing the machine to operate in full program run mode22. How the various types of materials will affect the feeds and voltage that can be used23. The application of dielectric fluids with regard to a range of different materials24. Typical problems that can occur when setting-up electrodes/wires in cartridges/holders/feed mechanisms and with

using workholding devices, and what to do if problems occur25. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


211





required)evidence typedate activities during setting up (all)correct operating programelectrode wire correct typedielectric fluid appropriate levelposition/secure workpiececheck safety devicesapply safe working practiceselectro discharge machine operation (one)NC spark or wire erosion machineCNC spark or wire erosion machineposition and secure workpieces (three)clamping direct to machine tablepneumatic or magnetic tablemachine vice angle plate vee block and clampsfixtureschucksancillary indexing deviceselect, load and set appropriate tool holding device (one)plain electrodesprofile electrodeshollow electrodeswiresprepare the tooling by carrying out the following activities (all)pre-setting electrodesloading and threading wirepositioning electrode cartridges/holderschecking electrode cartridges/holdersentering all wire dataentering all relevant tooling datasetting tool/wire datum pointsaving changes



212


required)evidence typedate set up to produce machined components (ten)flat facesparallel facestapered facesangular facesopen ended slots/recessesfaces square to each otherholes on pitch circlesinternal profilesexternal profilesparallel and tapered steps/slots/shoulderscircular/curved profilesenclosed slots/recessestapered holes linear holesspecial profilesother special forms of activitiesmachine components material (one)ferrousnon-ferrousprove machine is operating to required specification (all)equivalent to bs4500/bs1916 grade 7flatness and squareness 0.001” per inch or 0.025mm per 25mmcomponents to be free from false starts and sharp edgessurface finish 32µin/0.8µm 18vdimachined holes within h8angles within +/- 0.5 degree


Candidate: Date:

Assessor: Date:


213

Unit No 43: Machining Components using NC/CNC Electro Discharge Machines

Unit Summary

This unit identifies the competencies you need to operate Numerically Controlled (NC) or Computer Numerically Controlled (CNC) electrical discharge machines, such as spark erosion, tape erosion and wire erosion machines, in accordance with approved procedures. You will take charge of the prepared machine and check that it is ready for the machining operations to be performed. This will involve checking that all the required components and consumables are present and that the machine has been approved for production. In operating the machine, you will be expected to follow the correct procedures for calling up the operating program, dealing with any error messages, and executing the program activities safely and correctly.

The components produced will have a number of different features, including such things as flat, tapered and angled faces, internal and external profiles, parallel and tapered slots and steps, parallel and tapered holes which are linearly or circularly pitched, and special profiles such as convex or concave. You will be required to continuously monitor themachining operations, making any necessary adjustments to machine parameters, in line with your permitted authority. Meeting production targets will be an important issue and your production records must show consistent and satisfactory performance.

Your responsibilities will require you to comply with organisational policy and procedures for the activities undertaken, and to report any problems with the equipment, tooling, program, materials or activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work to instructions, taking personal responsibility for your own actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will be sufficient to provide a good understanding of your work, and will enable you to adopt an informed approach to applying NC/CNC electrical discharge procedures. You will have an understanding of the NC/CNC electrical discharge machining process, and its application, and will know about the equipment, tooling, materials and consumables, in adequate depth to provide a sound background to the machine operation and for carrying out the activities to the required specification.

You will understand the safety precautions required when working with the NC/CNC electro discharge machine and its associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.



214

Unit No 43: Machining Components using NC/CNC Electro Discharge MachinesPerformance statements:





• machine guards are in place and correctly adjusted• components are correctly positioned and held securely without distortion• the electrode or wire is in place and is in usable condition• the dielectric fluid is at an appropriate level• the operating program is at the correct start point • the workpiece is clear of the machine spindle• safe working practices and startup procedures are observed• machine settings are adjusted as required to maintain accuracy

2. Operate one of the following NC/CNC electrical discharge machines: • NC spark or wire erosion machine• CNC spark or wire erosion machine• CNC electrical discharge machining centre

3. Produce machined components which combine different operations, and cover ten of the following:● flat faces ● angular faces● tapered faces● parallel faces

faces square to each other

● external profiles● internal profiles● enclosed slots/recesses● open ended slots/recesses● tapered holes

● holes on pitch circles ● linear holes (rows, angles)● special profiles (eg, concave, convex)● other special forms or activities

● parallel and tapered steps/slots/shoulders ● circular/curved profiles (internal and external)

engravingthreads

4. Machine components made from one of the following types of material: • ferrous• non-ferrous

5. Produce components within all of the following quality and accuracy standards:● dimensional tolerance equivalent to BS4500 or BS 1916 Grade 7● flatness and squareness 0.001” per inch or 0.025mm per 25mm● components to be free from false starts and sharp edges● angles within +/- 0.5 degree ● machined holes within H8 ● surface finish 32 µin; 0.8µm; 18VDI

6. Carry out the necessary checks during production for accuracy of five of the following:● dimensions● position● parallelism● angle/taper

● squareness● surface texture● profile


215

Unit No 43: Machining Components using NC/CNC Electro Discharge MachinesKnowledge statements:


1. The specific safety precautions to be taken when working with NC/CNC electrical discharge machines and equipment2. The safety mechanisms on the machine, and the procedures for checking that they are operating correctly3. How to start and stop the machine in both normal and emergency situations4. The importance of wearing the appropriate protective clothing and equipment, and of keeping the work area clean

and tidy5. The hazards associated with the electro discharge machining operations (such as moving machine parts, electrical

components, handling dielectrics, fumes), and how they can be minimised6. The application of a range of NC/CNC electrical discharge machines such as spark erosion and wire erosion machines7. How to use and extract information from engineering drawings and related specifications, to include symbols and



program12. The operation of the various hand and automatic modes of machine control (such as hand wheels, joysticks, program

operating and control buttons)13. How to operate the machine, using single block run, full program run and feed/speed override controls14. How to make adjustments to the program operating parameters to take account of electrode wear15. How to set and secure the workpiece to the machine table/workholding device; the effects of clamping the

workpiece; and how material removal can cause warping/distortion of the finished workpiece16. The various types of electrodes/wire used, and how they are located and secured to the machine head, tool cartridge

and tool magazine17. The safe and correct handling and storage of tooling18. How to check that the electrode/wire is in a serviceable condition, and the effects that worn tooling will have on the

workpiece surface finish and tolerances19. The procedures for dressing and reshaping electrodes, and the equipment to be used20. The problems that can occur with electrical discharge activities, and how these can be overcome21. The application of dielectric and ionised fluids with regard to different materials being machined22. The quality control procedures used, inspection checks that need to be carried out, and the equipment that is used23. Where to obtain component drawings, eroding data, specifications and/or job instructions required for the

components being machined24. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


216





required)evidence typedate machine is ready for operation (all)machine guards in place and adjustedcomponents correctly positioned and held securelyelectrode wire in placedielectric fluid leveloperating program at start pointworkpiece is clear safe working practices and startup proceduresmachine setting adjustedoperate NC/CNC electrical discharge machines (one)NC spark wire erosion machineCNC spark wire erosion machineCNC electrical discharge machining centreproduce machined components which combine different operations (ten)flat facesangular facestapered facesparallel facesfaces square to each otherparallel and tapered steps/slots/shoulderscircular/curved profiles external profilesinternal profilesenclosed slots/recessesopen ended slots/recessestapered holesengraving threadsholes on pitch circleslinear holes (rows, angles)special profiles other special formsmachine components material (one)ferrousnon-ferrousproduce components to quality and accuracy standards (all)equivalent to BS4500/BS1916 grade 7flatness and sharpness 0.001” or 0.025mm per 25mmcomponents to be free from false starts and sharp edgesangles within +/- 0.5 degreemachined holes within h8surface finish 32µin 0.8µm 18vdi






217

required)evidence typedatecarry out necessary checks during production for accuracy (five)dimensionspositionparallelismangle/tapersquarenesssurface textureprofile


Candidate: Date:

Assessor: Date:


218

Unit No 44: Setting NC/CNC Vertical Boring Machines for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up Numerical Controlled (NC), or Computer Numerical Controlled (CNC) vertical boring machines, in accordance with approved procedures. You will be expected to select the appropriate workholding devices to be used, and to mount and position them to the machine in the correct location for the type of operation being carried out. You will also be required to select the appropriate boring tools and cutters, check them for defects, and mount and secure them to the relevant tool holding devices and machine spindle.



Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting-up procedures used. You will understand the NC/CNC vertical boring machine used, and its application, and will know about the workholding devices, tooling, machine operating programmes and setting-up procedures, in adequate depth to provide a sound basis for setting-up the equipment, correcting faults and ensuring the work output is produced to the required specification.



219

Unit No 44: Setting NC/CNC Vertical Boring Machines for ProductionPerformance statements:




• confirm the correct operating program has been loaded• check the tooling is in a usable condition• position and secure the workpiece without distortion

• update program data as applicable• position and adjust machine guards• apply safe working practices at all times

2. Prepare one of the following NC/CNC vertical boring machine in readiness for production: ● NC vertical boring machine ● CNC vertical boring machine

3. Position and secure workpieces using four of the following workholding methods and devices:● clamping direct to machine table● machine vice (plain, swivel, universal)● three jaw chucks, hard jaws● pneumatic or magnetic table

● indexing/rotating device● vee block and clamps● three jaw chucks, soft jaws● angle plate

• other workholding devices● four jaw chucks• fixtures

4. Select and mount, in the appropriate tool holding device, eight of the following types of cutting tool:● boring bars● turning tools● chamfering tools

● recessing tools● profiling● form tools

● centre drills● twist/core drills● boring tools

● reamers● grinding wheels● milling cutters

5. Prepare the tooling for operation by carrying out all of the following activities, as applicable to the machine type:● positioning tools in the correct position in the tool posts, turrets, magazine or carousel ● checking tools have a specific tool number in relation to the operating program● entering all relevant tool data to the operating program (tool lengths, tool offsets, radius compensation)● pre-setting tooling using setting jigs/fixtures ● setting tool

datums● saving changes to programme

6. Set up the machine to produce components, combining several different operations, and cover ten from:● plain internal/external diameters• stepped diameters● tapered diameters● special forms (such as concave, convex)● angular faces● internal/external undercuts

● internal and external profiles● drilled holes● reamed holes● tapped holes● eccentric diameters

● screw threads● internal bores● chamfers and radii● bored holes● flat faces


8 Make trial components to prove machine is operating to required specification, to include all the following:● dimensional tolerance equivalent to BS4500 or BS 1916 Grade 7● surface finish 63µin or 1.6µm ● reamed and bored holes within H8● flatness and squareness 0.001” per inch or 0.025mm per 25mm● angles within +/- 0.5 degree● screw threads BS medium fit


220

Unit No 44: Setting NC/CNC Vertical Boring Machines for ProductionKnowledge statements:


1. The specific safety precautions to be taken when setting up workholding devices and tooling on NC/CNC vertical boring machines

2. How to start and stop the machine in normal and emergency situations3. The importance of ensuring the machine is isolated from the power supply before mounting cutting tools and

workholding devices4. The importance of wearing the appropriate protective clothing and equipment, and of keeping the work area clean and

tidy5. The hazards associated with working on NC/CNC vertical boring machines (such as use of moving machinery, automatic

machine operation, handling cutting tools, lifting and handling workholding devices, hot and airborne metal particles), and how they can be minimised

6. How to handle and store cutting tools and verified tapes and programs, safely and correctly7. How to use and extract information from engineering drawings and related specifications, to include symbols and

conventions to appropriate BS or ISO standards in relation to work undertaken8. How to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points

and system of tolerancing9. The range of workholding methods and devices that are used on NC/CNC vertical boring machines10. Why it is important to set the workholding device in relation to the machine datums and reference points11. The methods of setting the workholding devices, and the tools and equipment that can be used12. The range of cutting tools that are used on NC/CNC vertical boring machines, and typical applications13. How to check that the cutting tools are in a safe and serviceable condition14. The use of tungsten carbide, ceramic and diamond indexible tips, and the factors which will determine their selection and

use (the condition of material supplied, hardness of the material, the cutting characteristics of the material, tolerances to be achieved, component surface finish and specifications)


16. The advantages of using pre-set tooling, and how to set the tooling using setting jigs/fixtures17. The use of tool posts, magazines and carousels, and how to position and identify the tools in relation to the operating

program18. How to place the machine into the correct operating mode, and how to access the program edit facility in order to enter

tooling data (such as tool datums, positions, lengths, offsets and radius compensation)19. How to conduct trial runs, using single block run, dry run and feed/speed override controls20. The things that you need to check before allowing the machine to operate in full program run mode21. How the various types of materials will affect the feeds and speeds that can be used22. The application of cutting fluids with regard to a range of different materials, and why some materials do not require the

use of cutting fluids23. Typical problems that can occur with the setting up of the tooling and workholding devices, and what to do if they occur24. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


221





required)evidence typedate activities to follow during setup (all)confirm correct operating program has been loadedcheck tooling is usableposition and secure workpiecesupdate program dataposition and adjust machine guardsapply safe work practicesprepare NC/CNC vertical boring machine for production (one)NC vertical boring machineCNC vertical boring machineposition and secure workpieces (four)clamping direct to machine tablemachine vicethree jaw chunks, hard jawspneumatic or magnetic tableindexing/rotating devicevee block and clampsthree jaw chunks, soft jawsangle plateother workholding devicesfour jaw chunksmilling cuttersprepare the tooling for operation by (all)correctly positioning tools checking tools have specific tool numberentering all relevant tool datapre-setting tooling using jigs/fixturessetting tool datumssaving changescombining operations, set up machine to produce components (ten)internal/external diametersstepped diameterstapered diametersspecial formsangular facesinternal/external undercutsinternal/external profilesdrilled holesreamed holestapped holeseccentric diametersscrew threadsinternal bores chamfers and radiibored holesflat faces


222





required)evidence typedatemachine material (one)ferrousnon-ferrousstainlessnon-metalliccomponents to prove machine is operating to specifications(all)equivalent to BS4500/BS1916 grade 7surface finish 63µin or 1.6µmreamed/bored holes within h8flatness and squareness 0.001” 0.025mm per 25mmangles within +/- 0.5 degreescrew threads BS med fit


Candidate: Date:

Assessor: Date:


223

Unit No 45: Machining Components using NC/CNC Vertical Boring Machines

Unit Summary

This unit identifies the competencies you need to carry out vertical boring operations, in accordance with approved procedures, using Numerical Controlled (NC) machines, or Computer Numerical Controlled (CNC) Machines. You will take charge of the prepared machine and check that it is ready for the machining operations to be performed. This will involve checking that all the required components and consumables are present, and that the machine has been approved for production. In operating the machine, you will be expected to follow the correct procedures for calling up the operating program, dealing with any error messages, and executing the program activities safely and correctly.

The components produced will have a number of different features, including plain internal/external diameters, eccentric diameters, stepped diameters, chamfers and radii, special forms and profiles, tapered diameters, flat and angular faces, internal and external profiles, grooves/undercuts, drilled holes, and reamed and tapped holes. You will be required to continuously monitor the machining operations, making any necessary adjustments to machine parameters, in line with your permitted authority. Meeting production targets will be an important issue, and your production records must show consistent and satisfactory performance.


Your underpinning knowledge will be sufficient to provide a good understanding of your work, and will enable you to adopt an informed approach to applying NC/CNC vertical boring procedures. You will have an understanding of the NC/CNC vertical boring process, and its application, and will know about the machine, tooling, materials, machining activities and consumables, in adequate depth to provide a sound background to the machine operation and for carrying out the activities to the required specification.


Setting up of the machine, its tooling and associated workholding devices are the subjects of other units.


224

Unit No 45: Machining Components using NC/CNC Vertical Boring MachinesPerformance statements:




You must: 1. Confirm that the machine is ready for operation, by checking all of the following:


2. Operate one of the following NC/CNC vertical boring machines:• NC vertical boring machine• CNC vertical boring machine

3. Produce machined components which combine several different operations, and cover ten of the following: plain internal/external diametersstepped diameterstapered diametersspecial forms (such as concave, convex)angular facesinternal/external undercuts

internal and external profilesdrilled holesreamed holestapped holeseccentric diameters

screw threadsinternal boreschamfers and radiibored holesflat faces

4. Machine one of the following types of material:ferrousnon-ferrousstainlessnon-metallic

5. Produce components within all the relevant quality and accuracy standards:● dimensional tolerance equivalent to BS4500 or BS 1916 Grade 7● surface finish 63µin or 1.6µm ● reamed and bored holes within H8● flatness and squareness 0.001” per inch or 0.025mm per 25mm● angles within +/- 0.5 degree● screw threads BS medium fit

6. Carry out the necessary checks during production, for accuracy of five of the following:● external diameters● internal diameters● lengths/depths● reamed hole size/fit● taper/angles



225

Unit No 45: Machining Components using NC/CNC Vertical Boring MachinesKnowledge statements:


1. The specific safety precautions to be taken when working with NC/CNC vertical boring machines and equipment

2. The safety mechanisms on the machine, and the procedures for checking that they are operating correctly

3. How to start and stop the machine in both normal and emergency situations4. The hazards associated with working on NC/CNC vertical boring machines (such as use of moving

machinery, automatic machine operation, handling cutting tools, lifting and handling workholding devices,hot and airborne metal particles), and how they can be minimised


6. The application of a range of NC/CNC vertical boring machines7. How to use and extract information from engineering drawings and related specifications, to include

symbols and conventions to appropriate BS or ISO standards in relation to work undertaken8. How to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece

reference points and system of tolerancing9. How to interpret the visual display and understand the various messages displayed10. The function of error messages, and what to do when an error message is displayed11. How to find the correct restart point in the program when the machine has been stopped before

completion of the program12. The operation of the various hand and automatic modes of machine control (such as hand wheels,

joysticks, program operating and control buttons)13. How to operate the machine, using single block run, full program run and feed/speed override controls14. How to make adjustments to the program operating parameters to take account of tool wear15. How to set and secure the workpiece to the machine spindle/workholding device; the effects of clamping

the workpiece; and how material removal can cause warping/distortion of the finished workpiece16. The various types of cutting tools used, and how they are located and secured to the machine tool posts,

turrets, slides and tool magazine or carousel17. The safe and correct handling and storage of tooling18. How to check that the indexible tooling is in a serviceable condition, and the effects that worn tooling will

have on the workpiece surface finish and tolerances19. The problems that can occur with vertical boring activities, and how these can be overcome20. The application of cutting fluids with regard to different materials being machined21. The quality control procedures used, inspection checks that need to be carried out, and the equipment

that is used22. Where to obtain component drawings, specifications and/or job instructions required for the components

being machined23. The extent of your own responsibility and whom you should report to if you have problems that you

cannot resolve


226




additional evidence (if required)

evidence typedate machine is ready for operation (all)machine guards adjustedcomponents correctly positionedcutting tools in suitable conditionoperating program is correctworkpiece is clearsafe working practicesmachine settings adjustedNC/CNC vertical boring machine for production (one)NC vertical boring machineCNC vertical boring machinemachined components operation (ten) plain internal/external diametersstepped diameterstapered diametersspecial formsangular facesinternal/external undercutsinternal/external profilesreamed holestapped holeseccentric diametersscrew threadsinternal boreschamfers and radiibored holesflat facesmachine material (one)ferrousnon-ferrousstainlessnon-metalliccomponents to prove machine is operating (all)BS4500/BS 1916 grade 7surface finish 63µin or 1.6µmreamed/bored holes within H80.001” 0.025mm per 25mmangles within +/- 0.5 degreescrew threads BS medium fitcomponents within quality and accuracy standard (all)external diametersinternal diameterslengths/depthsreamed hole size/fittaper/anglesthread fitslot/recess widthsurface finishflatness of facessquareness of faces


Candidate: Date:

Assessor: Date:


227

Unit No 46: Setting NC/CNC Horizontal Boring Machines for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up Numerical Controlled (NC), or Computer Numerical Controlled (CNC) horizontal boring machines, in accordance with approved procedures. You will be expected to select the appropriate workholding devices to be used, and to mount and position them to the machine in the correct location for the type of operation being carried out. You will also be required to select the appropriate boring tools and cutters, check them for defects, and mount and secure them to the relevant tool holding devices and machine spindle.


Your responsibilities will require you to comply with organisational policy and procedures for the machine setting activities undertaken, and to report any problems with the equipment, tooling, programs or setting-up activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that youcarry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting-up procedures used. You will understand the NC/CNC horizontal boring machine used, and its application, and will know about the workholding devices, tooling, machine operating programmes and setting-up procedures, in adequate depth to provide a sound basis for setting-up the equipment, correcting faults and ensuring the work output is produced to the required specification.



228

Unit No 46: Setting NC/CNC Horizontal Boring Machines for Production Performance statements:





• update program data as is applicable• position and adjust machine guards• apply safe working practices at all times

2. Prepare one of the following NC/CNC boring machine in readiness for production:● NC horizontal boring machine ● CNC horizontal boring machine

3. Position and secure workpieces using four of the following workholding methods and devices: ● clamping direct to machine table● machine vice (plain, swivel, universal)● three jaw chucks, hard jaws● pneumatic or magnetic table

● indexing/rotating device● vee block and clamps● three jaw chucks, soft jaws● other work holding devices


4. Select and mount, in the appropriate tool holding device, eight of the following types of cutting tool: ● boring tools● turning tools

● chamfering tools● recessing tools

● facing tools● twist/core drills

● taps● reamers

● milling cutters● forming tools

5. Prepare the tooling for operation by carrying out all of the following activities, as applicable to the machine type:● positioning tools in the correct position in the tool posts, turrets, magazine or carousel ● checking tools have a specific tool number in relation to the operating program● entering all relevant tool data to the operating program (tool lengths, tool offsets, radius compensation)● setting tool datums ● pre-setting tooling using setting jigs/fixtures ● saving changes to programme

6. Set up the machine to produce components, combining several different operations, and cover eight from: ● bored holes through the workpiece● bored holes to a depth● external diameters● flat faces● internal and external profiles

● square and parallel faces● angular faces● slots● indexed or rotated forms

● grooves/undercuts● drilled holes● reamed holes● tapped holes


8. Make trial components to prove machine is operating to required specification, to include all the following: ● dimensional tolerance equivalent to BS4500 or BS 1916 Grade 7● surface finish 63µin or 1.6µm ● reamed and bored holes within H8● flatness and squareness 0.001” per inch or 0.025mm per 25mm● angles within +/- 0.5 degree● screw threads BS medium fit


229

Unit No 46: Setting NC/CNC Horizontal Boring Machines for Production Knowledge statements:


1. The specific safety precautions to be taken when setting up workholding devices and tooling on NC/CNC horizontal boring machines


workholding devices4. The importance of wearing the appropriate protective clothing and equipment, and of keeping the work area

clean and tidy5. The hazards associated with working on NC/CNC horizontal boring machines (such as use of moving

machinery, automatic machine operation, handling cutting tools, lifting and handling workholding devices, hotand airborne metal particles), and how to minimise them

6. How to handle and store cutting tools and verified tapes and programs, safely and correctly7. How to use and extract information from engineering drawings and related specifications, to include symbols

and conventions to appropriate BS or ISO standards in relation to work undertaken8. How to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece

reference points and system of tolerancing9. The range of workholding methods and devices that are used on NC/CNC horizontal boring machines10. Why it is important to set the workholding device in relationship to the machine datums and reference points11. The methods of setting the workholding devices, and the tools and equipment that can be used12. The range of cutting tools that are used on NC/CNC horizontal boring machines, and typical applications13. How to check that the cutting tools are in a safe and serviceable condition14. The use of tungsten carbide, ceramic and diamond indexible tips, and the factors which will determine their

selection and use (condition of material supplied, hardness of the material, cutting characteristics of the material, tolerances to be achieved, component surface finish and specifications)


16. The advantages of using pre-set tooling, and how to set the tooling using setting jigs/fixtures17. The use of tool posts, magazines and carousels, and how to position and identify the tools in relationship to the

operating program18. How to place the machine into the correct operating mode, and how to access the program edit facility in order

to enter tooling data (such as tool datums, positions, lengths, offsets and radius compensation)19. How to conduct trial runs, using single block run, dry run and feed/speed override controls20. The things that you need to check before allowing the machine to operate in full program run mode21. How the various types of materials will affect the feeds and speeds that can be used22. The application of cutting fluids with regard to a range of different materials, and why some materials do not require the use of cutting fluids

23. Typical problems that can occur with the setting-up of the tooling and workholding devices, and what to do if they occur

24. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


230





required)evidence typedate activities to carryout during setup (all)confirm correct operating program is loadedcheck tooling is in usable conditionposition/secure workpieceupdate program dataposition/adjust machine guardsapply safe working practicesprepare NC/CNC vertical boring machine for production (one)NC horizontal boring machineCNC horizontal boring machineposition and secure workpieces (four)clamping direct to machine tablemachine vicethree jaw chucks (hard)pneumatic/magnetic tableindexing/rotating devicevee block and clampsthree jaw chucks (soft)other work holding devicesfour jaw chucksfixturesangle plateselect and mount, in the appropriate tool holding device (four)boring toolsturning toolschamfering toolsrecessing toolsfacing toolstwist/core drillstapsreamersmilling cuttersforming toolsprepare the tooling for operation (all)positioning tools correctlycheck tools have specific numberentering all relevant tool datasetting tool datumspre-setting toolingsaving changes to program



231


required)evidence typedate setup machine to produce components, combining operations (eight)bored holes through workpiece

bored holes to a depth

external diameters

flat faces

internal/external profilessquare/parallel facesangular facesslotsindexed/rotated formsgrooves/undercutsdrilled holesreamed holestapped holesmachine material (one)ferrousnon-ferrousstainlessnon-metallicmake trial components to prove machine is operating (all)dimension tolerance equivalent to BS4500/BS1916 grade 7surface finish 63µin or 1.6µmreamed/bored holes within h8flatness and squareness to 0.001” 0.025mm per 25mmangles within +/- 0.5 degreescrew threads BS medium fitflatness of facessquareness of faces


Candidate: Date:

Assessor: Date:


232

Unit No 47: Machining Components using NC/CNC Horizontal Boring Machines

Unit Summary

This unit identifies the competencies you need to carry out horizontal boring operations, in accordance with approved procedures, using Numerical Controlled (NC) machines, or Computer Numerical Controlled (CNC) machines. You will take charge of the prepared machine and check that it is ready for the machining operations to be performed. This will involve checking that all the required components and consumables are present, and that the machine has been approved for production. In operating the machine, you will be expected to follow the correct procedures for calling up the operating program, dealing with any error messages, and executing the program activities safely and correctly.

The components produced will have a number of different features, including bored holes to a depth and through the workpiece, tapered holes, external diameters, flat faces, square and parallel faces, angular faces, slots, indexed or rotated forms, internal and external profiles, grooves/undercuts, and drilled, reamed and tapped holes to depth and through the workpiece. You will be required to continuously monitor the machining operations, making any necessary adjustments to machine parameters, in line with your permitted authority. Meeting production targets will be an important issue, and your production records must show consistent and satisfactory performance.


Your underpinning knowledge will be sufficient to provide a good understanding of your work, and will enable you to adopt an informed approach to applying NC/CNC horizontal boring procedures. You will have an understanding of the NC/CNC horizontal boring process, and its application, and will know about the machine, tooling, materials, machining activities and consumables, in adequate depth to provide a sound background to the machine operation and for carrying out the activities to the required specification.




233

Unit No 47: Machining Components using NC/CNC Horizontal Boring MachinesPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Confirm that the equipment is set up and ready for operationc. Follow the defined procedures for starting and running the operating systemd. Deal promptly and effectively with error messages or equipment faults that are within your control and report those that

cannot be solvede. Monitor the computer process and ensure that the production output is to the required specificationf. Shut down the equipment to a safe condition on conclusion of the activities




2. Operate one of the following NC/CNC horizontal boring machines:• NC horizontal boring machine• CNC horizontal boring machine

3. Produce components which combine several different operations and cover eight of the following:● bored holes through the workpiece● bored holes to a depth● tapered holes● external diameters● flat faces● square and parallel faces● angular faces

● slots● indexed or rotated forms● grooves/undercuts● drilled holes● reamed holes● tapped holes ● internal and external profiles

4. Machine one of the following types of material:• ferrous• non-ferrous

• stainless• non-metallic

5. Produce components within all the relevant quality and accuracy standards:● dimensional tolerance equivalent to BS4500 or BS 1916 Grade 7● surface finish 63µin or 1.6µm ● reamed and bored holes within H8● flatness and squareness 0.001” per inch or 0.025mm per 25mm

6. Carry out the necessary checks during production, for accuracy of six of the following:● external diameters● internal diameters● lengths/depths● reamed hole size/fit● taper/angles



234

Unit No 47: Machining Components using NC/CNC Horizontal Boring MachinesKnowledge statements:


1. The specific safety precautions to be taken when working with NC/CNC horizontal boring machines and equipment

2. The safety mechanisms on the machine, and the procedures for checking that they are operating correctly3. How to start and stop the machine in both normal and emergency situations4. The hazards associated with working on NC/CNC horizontal boring machines (such as use of moving

machinery, automatic machine operation, handling cutting tools, lifting and handling workholding devices, hot and airborne metal particles), and how to minimise them


6. The application of a range of NC/CNC horizontal boring machines7. How to use and extract information from engineering drawings and related specifications, to include symbols


reference points and system of tolerancing9. How to interpret the visual display and understand the various messages displayed10. The function of error messages, and what to do when an error message is displayed11. How to find the correct restart point in the program when the machine has been stopped before completion of

the program12. The operation of the various hand and automatic modes of machine control (such as hand wheels, joysticks,

program operating and control buttons)13. How to operate the machine, using single block run, full program run, and feed/speed override controls14. How to make adjustments to the program operating parameters to take account of tool wear15. How to set and secure the workpiece to the machine spindle/workholding device; the effects of clamping the

workpiece; and how material removal can cause warping/distortion of the finished workpiece16. The various types of cutting tools used, and how they are located and secured to the machine tool posts,

turrets, slides and tool magazine or carousel17. The safe and correct handling and storage of tooling18. How to check that the indexible tooling is in a serviceable condition, and the effects that worn tooling will have

on the workpiece surface finish and tolerances19. The problems that can occur with horizontal boring activities, and how these can be overcome20. The application of cutting fluids with regard to different materials being machined21. The quality control procedures used, inspection checks that need to be carried out, and the equipment that is

used22. Where to obtain component drawings, specifications and/or job instructions required for the components being

machined23. The extent of your own responsibility and whom you should report to if you have problems that you cannot

resolve


235





required)evidence typedate confirm machine is ready for operation by checking (all)machine guards in place / adjustedcomponents correctly positioned and held securelycutting tools in suitable conditionoperating program at correct start pointworkpiece is clearsafe working practices/startup procedures observedmachine settings adjustedoperate NC/CNC vertical boring machine (one)NC horizontal boring machineCNC horizontal boring machineproduce components which combine different operations (eight)bored holes through workpiecebored holes to a depthtapered holesexternal diametersflat facessquare/parallel faces angular facesslotsindexed or rotated formsgrooves/undercutsdrilled holesreamed holestapped holesinternal/external profilesmachine material (one)ferrousnon-ferrousstainlessnon-metallicproduce components to standards (all)dimensional tolerance BS4500/BS1916 grade 7surface finish 63µin or 1.6µmreamed/bored holes within H8flatness and squareness 0.001” 0.025mm per 25mm


236





required)evidence typedate apply checks during production (eight)external diametersinternal diameterslengths/depthsreamed hole size/fittaper/anglesthread fitslot/recess widthsurface finishflatness of facessquareness of faces


Candidate: Date:

Assessor: Date:


237

Unit No 48: Setting NC/CNC Gear Cutting Machines for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up Numerical Controlled (NC), or Computer Numerical Controlled (CNC) gear cutting machines, in accordance with approved procedures. You will be expected to select the appropriate workholding devices to be used, and to mount and position them to the machine in the correct location for the type of operation being carried out. You will also be required to select the appropriate tools and cutters, check them for defects, and mount and secure them to the relevant tool holding devices and machine spindle.

You will need to ensure that all the tools have been allocated a relevant tool number, and that the relevant data on their co-ordinates and datum positions are entered into the operating program and machine. This will involve loading and proving component programmes, checking for errors/faults, editing and saving program changes. You must produce trial components and prove the machine is working satisfactorily before declaring the machine ready for production. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.


Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting-up procedures used. You will understand the NC/CNC gear cutting machine used, and its application, and will know about the workholding devices, tooling, machine operating programmes and setting-up procedures, in adequate depth to provide a sound basis for setting-up the equipment, correcting faults and ensuring the work output is produced to the required specification.



238

Unit No 48: Setting NC/CNC Gear Cutting Machines for ProductionPerformance statements:





• update program data as applicable• position and adjust machine guards• apply safe working practices at all times

2. Prepare one of the following NC/CNC gear cutting machines in readiness for production:● NC gear cutting machine ● CNC gear hobbing machine ● CNC gear shaving machine

3. Position and secure workpieces using four of the following workholding methods and devices:● arbors● mandrels

● chucks● pots

● collets● fixtures

● centres● clamps

● face plates

4. Select and mount, in the appropriate tool holding device, three of the following types of cutting tool:● hobs● shaving tools

● bevel gear cutting tools● rack cutting tools

● spline/serration cutting tools● other cutting tools

5. Prepare the tooling by carrying out all of the following activities, as applicable to the machine type:● positioning tools in the correct position in the turrets, magazine or carousel● checking tools have a specific tool number in relation to the operating program● entering all relevant tool data to the operating program (tool lengths, tool offsets)● setting tool datums● pre-setting tooling using setting jigs/fixtures● saving changes to programme

6. Set up the machine to produce components combining several different operations, and cover four from:● external spur gears● internal spur gears● external helical gears

● internal helical gears● straight splines● involute splines

● serrations● bevel gears● racks


8. Make trial components to prove machine is operating to required specification, to include all the following:● components to be free from false tool cuts, burrs and sharp edges● straight splines and serrations to BS 2059 or BS1953 Class 1● spur and helical gears to BS 436 Pt 1 or BS1967● involute splines to BS 3550 1963 Class 1● tolerance to BS 4500 or BS1916 Grade 9● surface texture 63 µin or 1.6µm


239

Unit No 48: Setting NC/CNC Gear Cutting Machines for ProductionKnowledge statements:


1. The specific safety precautions to be taken when setting up workholding devices and tooling on NC/CNC gear cutting machines

2. How to start and stop the machine in normal and emergency situations3. The importance of ensuring the machine is isolated from the power supply before mounting cutting tools

and workholding devices4. The importance of wearing the appropriate protective clothing and equipment, and of keeping the work

area clean and tidy5. The hazards associated with working on NC/CNC gear cutting machines (such as use of moving


6. How to handle and store cutting tools and verified tapes and programs, safely and correctly7. How to use and extract information from engineering drawings and related specifications, to include


reference points and system of tolerancing9. The range of workholding methods and devices that are used on NC/CNC gear cutting machines10. Why it is important to set the workholding device in relationship to the machine datums and reference

points11. The methods of setting the workholding devices, and the tools and equipment that can be used12. The range of cutting tools used on NC/CNC gear cutting machines, and typical applications13. The different types of gears and their application14. How to check that the cutting tools are in a safe and serviceable condition15. The use of tungsten carbide, ceramic and diamond indexible tips, and the factors which will determine

their selection and use (condition of material supplied, hardness of the material, cutting characteristics of the material, tolerances to be achieved, component surface finish and specifications)


17. The advantages of using pre-set tooling, and how to set the tooling using setting jigs/fixtures18. The use of magazines and carousels, and how to position and identify the tools in relation to the

operating program19. How to place the machine into the correct operating mode, and how to access the program edit facility in

order to enter tooling data (such as tool datums, positions, lengths, offsets and radius compensation)20. How to conduct trial runs, using single block run, dry run and feed/speed override controls21. The things that you need to check before allowing the machine to operate in full program run mode22. How the various types of materials will affect the feeds and speeds that can be used23. The application of cutting fluids with regard to a range of different materials, and why some materials do

not require the use of cutting fluids24. Typical problems that can occur with the setting-up of the tooling and workholding devices, and what to

do if they occur.25. The extent of your own responsibility and whom you should report to if you have problems that you

cannot resolve


240





required)evidence typedate activities to carryout during setup (all)confirm correct operating program has been loadedcheck tooling is in useable conditionposition/secure workpieceupdate program dataposition/adjust machine guardsapply safe working practicesNC/CNC vertical boring machine for production (one)NC gear cutting machineCNC gear hobbing machineCNC gear shaving machineposition and secure workpieces (four)arborsmandrelschuckspotscolletsfixturescentresclampsface platesselect and mount appropriate tool holding device (three)hobsshaving toolsbevel gear cutting toolsrack cutting toolsspline/serration cutting toolsother cutting toolsprepare tooling as applicable to machine type (all)positioning tools correctlycheck tools have specific numberentering tool datasetting tool datumspre-setting toolingsaving changes to programmesetup machine to produce components, combining operations (four)external spur gearsinternal spur gearsexternal helical gearsinternal helical gearsstraight splinesinvolute splinesserrationsbevel gearsracks


241





required)evidence typedate machine material (one)ferrousnon-ferrousstainlessnon-metallicmake trail components to prove machine is operating to specification (all)components to be free from false tool cuts, burrs and sharp edgesstraight splines/serrations to BS2059/BS1953 class 1spur/helical gears to BS436 Pt 1/ BS1967involute splines to BS3550 1963 class 1tolerance to BS4500/ BS1916 grade 9surface texture 63 µin or 1.6µm


Candidate: Date:

Assessor: Date:


242

Unit No 49: Machining Components using NC/CNC Gear Cutting Machines

Unit Summary

This unit identifies the competencies you need to carry out gear cutting operations, in accordance with approved procedures, using Numerical Controlled (NC) machines, or Computer Numerical Controlled (CNC) machines. You will take charge of the prepared machine and check that it is ready for the machining operations to be performed. This will involve checking that all the required components and consumables are present and that the machine has been approved for production. In operating the machine, you will be expected to follow the correct procedures for calling up the operating program, dealing with any error messages, and executing the program activities safely and correctly.

The components produced will have a number of different features, including internal and external spur gears, helical gears, involute splines, straight splines, serrations, racks and bevel gears. You will be required to continuously monitor the machining operations, making any necessary adjustments to machine parameters, in line with your permitted authority. Meeting production targets will be an important issue, and your production records must show consistent and satisfactory performance.

Your responsibilities will require you to comply with organisational policy and procedures for the gear cutting activities undertaken, and to report any problems with the equipment, tooling, program, materials or activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will be sufficient to provide a good understanding of your work, and will enable you to adopt an informed approach to applying NC/CNC gear cutting procedures. You will have an understanding of the NC/CNC gear cutting process, and its application, and will know about the machine, tooling, materials, machining activities and consumables, in adequate depth to provide a sound background to the machine operation and for carrying out the activities to the required specification.




243

Unit No 49: Machining Components using NC/CNC Gear Cutting MachinesPerformance statements:






2. Operate one of the following NC/CNC gear cutting machines:● NC gear cutting machine● CNC gear hobbing machine● CNC gear shaving machine

3. Produce machined components which combine several different operations and cover four of the following:● external spur gears● internal spur gears● external helical gears● internal helical gears● straight splines

● involute splines● serrations● bevel gears● racks

4. Machine one of the following types of material:ferrousnon-ferrousstainlessnon-metallic

5. Produce components within all the relevant quality and accuracy standards: ● components to be free from false tool cuts, burrs and sharp edges● straight splines and serrations to BS 2059 or BS1953 Class 1● spur and helical gears to BS 436 Pt 1 or BS1967● involute splines to BS 3550 1963 Class 1● tolerance to BS 4500 or BS1916 Grade 9● surface texture 63 µin or 1.6µm

6. Carry out the necessary checks during production, for accuracy of five of the following:● gear blanks● lead and helix angle● gear tooth thickness

● involute form● composite error rolling test● surface texture


244

Unit No 49: Machining Components using NC/CNC Gear Cutting MachinesKnowledge statements:


1. The specific safety precautions to be taken when working with NC/CNC gear cutting machines and equipment


3. How to start and stop the machine in both normal and emergency situations4. The hazards associated with working on NC/CNC gear cutting machines (such as use of moving



6. The application of a range of NC/CNC gear cutting machines7. How to use and extract information from engineering drawings and related specifications, to include





the workpiece; and how material removal can cause warping/distortion of the finished workpiece16. The various types of cutting tools used, and how they are located and secured to the machine tool posts,


have on the workpiece surface finish and tolerances19. The problems that can occur with gear cutting activities, and how these can be overcome20. The application of cutting fluids with regard to different materials being machined21. The quality control procedures used, inspection checks that need to be carried out, and the equipment



cannot resolve


245




additional evidence (if

required)evidence typedate confirm/check machine is ready for operation (all)machine guards in place / correctly adjustedcomponents correctly positioned / held securelycutting tools in suitable conditionoperating program at correct start pointworkpiece is clear safe working practices / startup procedures observedmachine settings adjustedoperate NC/CNC gear cutting machine (one)NC gear cutting machineCNC gear hobbing machineCNC gear shaving machineproduce machine components which combine different operations (four)external spur gearsinternal spur gearsexternal helical gearsinternal helical gearsstraight splinesinvolute splinesserrationsbevel gearsracksmachine material (one)ferrousnon-ferrousstainlessnon-metallicproduce components to standards (all)components free from false tool cuts, burrs/sharp edgesstraight spines and serration to BS2059/BS1953 class 1spur and helical gears to BS436 Pt 1/ BS1967involute splines to BS3550 1963 class 1tolerance to BS4500/BS1916 grade 9surface texture 63µin or 1.6µmapply checks during production (five)gear blankslead and helix anglegear tooth thicknessinvolute formcomposite error rolling testsurface texture


Candidate: Date:

Assessor: Date:


246

Unit No 50: Setting NC/CNC Machining Centres for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up Numerically Controlled (NC) or Computer Numerical Controlled (CNC) machining centres, in accordance with approved procedures. You will be expected to select the appropriate workholding devices to be used, and to mount and position them to the machine in the correct location for the type of operation being carried out. You will also be required to select the appropriate tools and cutters, check them for defects, and mount and secure them to the relevant tool holding devices and machine spindle.

You will need to ensure that all the tools have been allocated a relevant tool number, and that the relevant data on their co-ordinates and datum positions are entered into the operating program and machine. This will involve loading and proving component programs, checking for errors/faults, editing and saving program changes. You must produce trial components and prove the machine is working satisfactorily before declaring the machine ready for production. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.


Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting-up procedures used. You will understand the NC/CNC machining centre used, and its application, and will know about the workholding devices, tooling, machine operating programs and setting-up procedures, in adequate depth to provide a sound basis for setting up the equipment, correcting faults and ensuring the work output is produced to the required specification.



247

Unit No 50: Setting NC/CNC Machining Centres for Production Performance statements:





2. Prepare one of the following NC/CNC machining centres in readiness for production: ● NC machining centre ● CNC machining centre

3. Position and secure workpieces using four of the following workholding methods and devices:● clamping direct to machine table● vee blocks and clamps● machine vice● chucks with hard jaws

● chucks with soft jaws● collet chucks● jigs and fixtures● angle plate

● indexing/rotating device● magnetic or pneumatic tables● other work holding devices

4. Select and mount in the appropriate tool holding device, eight of the following types of cutting tool:● turning tools● boring tools● facing● thread cutting tools

● twist/core drills● reamers● recessing/undercutting tools● face mills

● slotting cutters● slitting saws● end mills

● slot drills● grinding wheels● taps

5. Prepare the tooling for operation by carrying out all of the following activities as applicable to the machine type:● positioning tools in the correct position in the turrets, magazine or carousel ● checking tools have a specific tool number in relationship to the operating program● entering all relevant tool data to the operating program (tool lengths, tool offsets, radius compensation)● setting tool datums ● pre-setting tooling using setting jigs/fixtures ● saving changes to programme

6. Set up the machine to produce components combining several different operations and cover ten from: ● external diameters● tapered diameters● shoulders and steps● bored holes

● square and parallel faces ● angular faces● indexed or rotated forms● internal and external profiles

● grooves/undercuts● drilled● holes● flat faces

● reamed holes● tapped holes ● slots● tapered holes


8. Make trial components to prove machine is operating to required specification, to include all the following:● dimensional tolerance equivalent to BS4500 or BS 1916 Grade 7● components to be free from false tool cuts, burrs and sharp edges● flatness and squareness 0.001” per inch or 0.025mm per 25mm ● reamed/bored holes within H8● angles within +/- 0.5 degree ● screw threads BS medium fit ● surface finish 63µin or 1.6µm


248

Unit No 50: Setting NC/CNC Machining Centres for Production Knowledge statements:


1. The specific safety precautions to be taken when setting up workholding devices and tooling on NC/CNC machining centres



clean and tidy5. The hazards associated with working on NC/CNC machining centres (such as use of moving machinery,


6. How to handle and store cutting tools and verified tapes and programs safely and correctly7. How to use and extract information from engineering drawings and related specifications, to include symbols


reference points and system of tolerancing9. The range of workholding methods and devices that are used on NC/CNC machining centres10. Why it is important to set the workholding device in relation to the machine datums and reference points11. The methods of setting the workholding devices, and the tools and equipment that can be used12. The range of cutting tools used on NC/CNC machining centres, and typical applications13. How to check that the cutting tools are in a safe and serviceable condition14. The use of tungsten carbide, ceramic and diamond indexible tips, and the factors which will determine their

selection and use (condition of material supplied, hardness of the material, cutting characteristics of thematerial, tolerances to be achieved, component surface finish and specifications)


16. The advantages of using pre-set tooling, and how to set the tooling using setting jigs/fixtures17. The use of magazines and carousels, and how to position and identify the tools in relation to the operating

program18. How to place the machine into the correct operating mode, and how to access the program edit facility in order

to enter tooling data (such as tool datums, positions, lengths, offsets and radius compensation)19. How to conduct trial runs, using single block run, dry run and feed/speed override controls20. The things that you need to check before allowing the machine to operate in full program run mode21. How the various types of materials will affect the feeds and speeds that can be used22. The application of cutting fluids with regard to a range of different materials, and why some materials do not

require the use of cutting fluids23. Typical problems that can occur with the setting up of the tooling and workholding devices, and what to do if

they occur24. The extent of your own responsibility and whom you should report to if you have problems that you cannot

resolve


249





required)evidence typedate apply activities during setting up (all)confirm correct operating program has been loadedcheck the tooling is in usable conditionensure workpiece is correctly positioned / securedupdate program tool dataposition / adjust machine guardsapply safe working practicesprepare NC/CNC machining centres in preparation for production (one)NC machining centreCNC machining centreposition and secure workpieces using workholding methods and devices (four)clamping direct to machinevee blocks and clampsmachine vicechucks with hard jawschucks with soft jawsjigs and fixturesangle plateindexing/rotating devicemagnetic/pneumatic tablesother work holding devicesselect and mount in appropriate tool holding device (eight)turning toolsboring toolsfacingthread cutting toolstwist / core drillsreamersrecessing / undercutting toolsface millsslotting cuttersslitting sawsend millsslot drillsgrinding wheelstapsprepare the tooling for operation as applicable to machine type (all)positioning tools correctly in turrets / magazine / carouselchecking tools have specific tool numberentering tool data to operating programsetting tool datumspre-setting tooling using setting jigs / fixturessaving changes to programme


250





required)evidence typedate set up machine to produce components combining several different operations (ten)external diameterstapered diametersshoulders and stepsbored holessquare and parallel facesangular faces indexed or rotated formsinternal and external profilesgrooves / undercutsdrilledholesflat facesreamed holestapped holesslotstapered holesmachine material (one)ferrousnon-ferrousstainlessnon-metallicmake trial components to prove machine is operated to required specification (all)dimensional tolerance equivalent to BS4500/BS1916 grade 7components free from false tool cuts / burrs / sharp edgesflatness / squareness 0.001” 0.025mm per 25mmangles within +/-0.5 degreescrew threads BS medium fitreamed / bored holes within H8surface finish 63µin or 1.6µm


Candidate: Date:

Assessor: Date:


251

Unit No 51: Machining Components using NC/CNC Machining Centres

Unit Summary

This unit identifies the competencies you need to carry out operations, in accordance with approved procedures, using Numerical Controlled machines, or Computer Numerical Controlled (CNC) machining centres. You will take charge of the prepared machine and check that it is ready for the machining operations to be performed. This will involve checking that all the required components and consumables are present, and that the machine has been approved for production. In operating the machine, you will be expected to follow the correct procedures for calling up the operating program, dealing with any error messages, and executing the program activities safely and correctly.

The components produced will have a number of different features, including bored holes to a depth and through the workpiece, tapered holes, external diameters, flat faces, square and parallel faces, angular faces, slots, indexed or rotated forms, internal and external profiles, grooves/undercuts, and drilled, reamed and tapped holes to depth and through the workpiece. You will be required to continuously monitor the machining operations, making any necessary adjustments to machine parameters, in line with your permitted authority. Meeting production targets will be an important issue, and your production records must show consistent and satisfactory performance.

Your responsibilities will require you to comply with organisational policy and procedures for the activities undertaken, and to report any problems with the equipment, tooling, program, materials or activities that you cannot personallyresolve, or are outside your permitted authority, to the relevant people. You will be expected to work to with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will be sufficient to provide a good understanding of your work, and will enable you to adopt an informed approach to applying NC/CNC machining centre procedures. You will have an understanding of the NC/CNC machining centre process, and its application, and will know about the machine, tooling, materials, machining activities and consumables, in adequate depth to provide a sound background to the machine operation and for carrying out the activities to the required specification.




252

Unit No 51: Machining Components using NC/CNC Machining CentresPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Confirm that the equipment is set up and ready for operationc. Follow the defined procedures for starting and running the operating systemd. Deal promptly and effectively with error messages or equipment faults that are within your control and report

those that cannot be solvede. Monitor the computer process and ensure that the production output is to the required specificationf. Shut down the equipment to a safe condition on conclusion of the activities


You must: 1. Confirm that the machine is ready for operation by checking all of the following:

● machine guards are in place and correctly adjusted● components are correctly positioned and held securely without distortion● cutting tools are in a suitable condition● the operating program is at the correct start point ● the workpiece is clear of the machine spindle● safe working practices and startup procedures are observed● machine settings are adjusted as required to maintain accuracy

2. Operate one of the following NC/CNC machining centres: NC machining

centre● CNC machining centre

3. Produce components which combine several different operations and cover ten of the following:● external diameters● tapered diameters● shoulders and steps● bored holes● tapered holes● flat faces● tapped holes

● square and parallel faces ● angular faces● slots● indexed or rotated forms● internal profiles● external profiles● internal threads

● external threads● grooves● undercuts● drilled● holes● reamed holes

4. Machine one of the following types of material:ferrousnon-ferrous

stainlessnon-metallic

5. Produce components within all of the following quality and accuracy standards:● dimensional tolerance equivalent to BS4500 or BS 1916 Grade 7● components to be free from false tool cuts, burrs and sharp edges● flatness and squareness 0.001” per inch or 0.025mm per 25mm● reamed/bored holes within H8● angles within +/- 0.5 degree● screw threads BS medium fit● surface finish 63µin or 1.6µm

6. Carry out the necessary checks during production, for accuracy of five of the following:● external diameters● internal diameters● lengths/depths● reamed hole size/fit● taper/angles

● thread fit● slot or recess width and position ● surface finish● flatness of faces ● squareness of faces


253

Unit No 51: Machining Components using NC/CNC Machining CentresKnowledge statements:


1. The specific safety precautions to be taken when working with NC/CNC machining centre and equipment


3. How to start and stop the machine in both normal and emergency situations4. The hazards associated with working on NC/CNC machining centres (such as use of moving machinery,



6. The application of a range of NC/CNC machining centres7. How to use and extract information from engineering drawings and related specifications, to include





the workpiece; and how material removal can cause warping/distortion of the finished workpiece16. The various types of cutting tools used, and how they are located and secured to the machine tool-posts,


have on the workpiece surface finish and tolerances19. The problems that can occur with horizontal boring activities, and how these can be overcome20. The application of cutting fluids with regard to different materials being machined21. The quality control procedures used, inspection checks that need to be carried out, and the equipment



cannot resolve


254





required)evidence typedate confirm machine is ready for operation by checking (all)machine guards in place / correctly adjustedcomponents correctly positioned / held securelycutting tools in suitable conditionoperating program at correct stating pointwork piece is clearsafe working practices / start up procedures observedmachine settings adjustedoperate NC/CNC machining centres (one)NC machining centreCNC machining centreproduce components which combine operations (ten)external diameterstapered diametersshoulders and stepsbored holestapered holesflat facestapped holessquare and parallel facesangular facesslotsindexed or rotated formsinternal profilesexternal profilesinternal threadsexternal threadsgroovesundercutsdrilledholesreamed holesmachine material (one)ferrousnon-ferrousstainlessnon-metallicproduce components to standards (all)dimensional tolerance equivalent to BS4500 / BS1916 grade 7components free from false tool cuts/burrs/sharp edgesflatness and squareness 0.001” 0.025mm per 25mmangles within +/-0.5 degreescrew threads BS medium fitreamed/bored holes within h8surface finish 63µin or 1.6µm


255





required)evidence typedate apply checks during production (five)external diametersinternal diameterslengths/depthsreamed hole size/fittaper/anglesthread fitslot or recess width and positionsurface finishflatness of facessquareness of faces


Candidate: Date:

Assessor: Date:


256

Unit No 52: Handing Over Machine Tools to Production Operators

Unit Summary

This unit identifies the competencies you need to hand over a prepared machine tool to production operators, in accordance with approved procedures. You will have either set up the machine yourself and are now handing it over to a machine operator to complete the required production operations, or are responsible for ensuring that a prepared machine already in production is handed over to a new shift operator. This will involve checking that the machine functions safely and correctly, that there are sufficient materials and consumables available for the work to be carried out, that all the required quality control instruments and gauges are available and correctly set/calibrated, and that the machine is producing the components to the required specification.

You must then demonstrate the operation of the machine to the operator, highlighting all the necessary key stages of performance, specific techniques to be used, and aspects of safety that require particular attention. You will be required to ensure that the operator is operating the machine safely and correctly before leaving him/her to perform the tasks unsupervised. Periodic checking of the finished components, making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.

Your responsibilities will require you to comply with organisational policy and procedures for the coaching and handover activities undertaken, and to report any problems with the handing over that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that is produced.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying coaching and handover procedures. You will understand the equipment being handed over, and its application, and will know about the operating procedures, potential problems and operating training requirements, in adequate depth to provide a sound basis for enabling the operators to carry out the activities to the required specification.

You will understand the safety precautions required when working with the machine and its associated equipment. You will be required to ensure that the production operator demonstrates safe working practices throughout, and that they understand the responsibility they owe to themselves and others in the workplace.


257

Unit No 52: Handing Over Machine Tools to Production OperatorsPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Check the machine and equipment is in a safe and usable condition to hand overc. Ensure that the prepared machine is producing the components to the required specificationd. Demonstrate the correct operation of the machine to the production operatore. Ensure the production operator understands the operation of the machine and the production requirements f. Make periodic checks of the production and, where appropriate, adjust machine settings to maintain the required

output qualityg. Deal promptly and effectively with problems within your control and report those that you cannot solveh. Maintain appropriate records of the hand over, in accordance with organisational procedures


You must:1. Confirm that the installation is ready for production operations, to include checking all of the following:

the machine is correctly set up and ready for the required production operationssupplies of components and consumables are adequate and correctly preparedall safety equipment is in place and functioning correctlyall machine functions operate correctlyappropriate quality control instruments and gauges are available and correctly calibrated

2. Carry out correct handing over procedures for one type of machine tool from the following: ● manual machines● semi-automatic machines● fully automatic machines● computer controlled machines● power presses

3. Carry out handover procedures which include all of the following:● demonstrating the operation of the machine to the production operator● explaining all the key stages and specific operation techniques required● highlighting critical areas to be observed (safety, specific tolerances or finish)● observing the operator in action and correcting any errors or inappropriate working practices● ensuring the operator is working safely and competently before leaving them to carry on with production● making periodic checks of performance and production quality

4. Carry out handover procedures on two of the following categories of production operators: ● experienced operators on the particular type of equipment being used● experienced operators on machines but not the equipment being used● new or inexperienced operators


258

Unit No 52: Handing Over Machine Tools to Production OperatorsKnowledge statements:


1. The specific safety precautions to be taken when working with machine tools and when handing over machine tools to production operators

2. The hazards associated with the particular machine and its operation, and how this needs to be communicated to the operator

3. The specific personal protective clothing and equipment that needs to be worn for the particularactivities, and how this is obtained

4. The need to be extra vigilant when training new and inexperienced machine operators to carry out thetasks

5. The things that you need to check before handing over the machine to the production operator (themachine is in a fit and safe condition, the tooling is sharp and undamaged, the machine producescomponents to specification)

6. The need to give the operator a practical demonstration of the machine operation, and how this is bestachieved

7. Practical training techniques, including questioning and reinforcement techniques, to ensure the requiredoperations are understood

8. How to vary your approach with the training, depending on the experience of the production operator9. The need to ensure that the production operators are working safely and competently before leaving

them to complete the production operations10. How to create and maintain effective working relationships with the operators (encouraging, helping,

politeness, open discussions both ways)11. Organisational documentation and procedures for training and handover activities12. The extent of your own responsibility and whom you should report to if you have problems that you

cannot resolve


259





required)evidence typedate confirm installation is ready for production operations (all)machine is correctly set up / readysupplies of components / consumables are adequate /correctly preparedsafety equipment in place/functioning properlymachine functions operate correctlyquality control instruments and gauges are available/ correctly calibratedapply correct handing over procedures (one)manual machinessemi-automatic machinesfully automatic machinescomputer controlled machinespower pressesapply handover procedures (all)demonstrate operation of machineexplain key stages/specific operation techniqueshighlight critical areas to be observedobserve operator- correct errors/inappropriate working practices ensure operator working safely before leavingmake checks of performance/ production qualityapply production operator handover procedures (two)experienced operators on particular type/equipment being usedexperienced operators on machines/equipment not being usednew/inexperienced operators


Candidate: Date:

Assessor: Date:


260

Unit No 53: Setting Capstan and Turret Lathes for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up capstan and turret lathes, in accordance with approved procedures. This will involve selecting the appropriate workholding devices, securing them to the machine spindle, selecting and setting suitable chuck jaws and collet chucks, boring out soft jaws, and mounting workpieces in jigs or fixtures. You will be expected to select the appropriate turning tools, check that they are in a usable condition, and mount and secure them to the relevant tool holding devices, in front and rear tool posts and on the capstan/turret head.

You will need to set the machine operating parameters to produce the workpiece to the required specification. This will involve setting up capstan/turret and saddle feed stops, setting appropriate depths of cut for roughing and finishing operations, selecting and setting feeds and speeds, and setting up multiple cutting arrangements between capstan/turret and saddle. You must produce trial cuts and prove the machine is working satisfactorily before declaring the machine ready for production. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.

Your responsibilities will require you to comply with organisational policy and procedures for the machine setting activities undertaken, and to report any problems with the machine, tooling, equipment or setting-up activities that you cannot resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting-up procedures used. You will understand the machine used, and its application, and will know about the workholding devices, turning tools, relevant materials, consumables and setting-up procedures, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the work output is to the required specification.


This unit does not cover NC/CNC turning activities, for which other units apply.


261

Unit No 53: Setting Capstan and Turret Lathes for Production Performance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the correct specifications for the component to be producedc. Determine what has to be done and how the machine will be set to achieve thisd. Mount and set the required work-holding devices, workpiece and cutting toolse. Set the machine tool operating parameters to achieve the component specificationf. Check that all safety mechanisms are in place and that the equipment is set correctly for the required operationsg. Deal promptly and effectively with problems within your control and report those that cannot be solved



● hold components securely without distortion ● check cutting tools are in a suitable condition

● apply safe working practices at all times● ensure correctly adjusted machine guards are in place




3. Use two of the following groups of turning tools: ● solid high-speed steel ● brazed tungsten carbide indexible tips (carbide, ceramic, diamond)

4. Select and mount roughing and finishing tools, to include eight of the following types of tools:turning toolsfacing toolsform toolschamfer/radius

parting off toolsthread chasersingle point threading boring bars

● recessing tools● centre drills ● twist/core drills● solid reamers


knurling tools5. Mount, secure and position tools in all of the following:

front tool box rear tool post ending boxes die boxes roller boxpolygon/special profile boxesturret/capstan knee box

boring bars (single / multiple)chucks/floating arrangements

multiple cutting arrangements

6. Set up machine in accordance with instructions and specifications, to include setting all of the following: ● position of workpiece in work holding device● position of turning tools in relationship to workpiece● screw threading devices● workpiece speed and feed

● depth of cut for roughing and finishing● turret and saddle feed stops and indicators● cutting fluid flow rate● machine guards/safety mechanisms




● chamfers and radii ● knurls/special finishes● grooves/undercuts● counterbores

8. Machine components made from one of the following types of material:● ferrous ● non-ferrous ● non-metallic

9. Make trial components to prove the machine is operating to required specification, to include all the following:● components to be free from false tool cuts, burrs and sharp edges● dimensional tolerance equivalent to BS 4500 or BS 1916 Grade 7● reamed and bored holes within H8

● screw threads BS medium fit● angles within +/- 0.5 degree● surface finish 63µin or 1.6µm


262

Unit No 53: Setting Capstan and Turret Lathes for Production Knowledge statements:


1. The specific safety precautions to be taken when setting up workholding devices and accessories, workpieceand turning tools on capstan and turret lathes

2. The hazards associated with capstan and turret lathes (moving parts of machinery, handling turning tools,handling cutting fluids, airborne particles, tool breakage, power chucks and power bar feed arrangements,insecure components), and how they can be minimised



clean and tidy6. The basic principles of operation of the capstan or turret lathe and its accessories, and typical operations that

they can perform7. How to handle and store turning tools safely and correctly8. How to use and extract information from engineering drawings and related specifications, to include symbols


reference points and system of tolerancing10. Terminology used in capstan and turret lathe turning in relation to the activities undertaken11. The range of workholding methods and devices that are used on capstan and turret lathes (two three and four

jaw chucks, hand and power operated chucks, power bar feed arrangements, collet chucks, jigs and fixtures)12. The use of hard and soft jaws in chucks, and the methods of boring out soft jaws to suit the workpiece13. The different types of turning tools that are used, and how they are selected, prepared and mounted to the

machine tool holding devices (front tool box, rear tool box, capstan/turret head, roller boxes, ending boxes,special profiling boxes, die boxes)

14. The use of pilot bars and shoes for the capstan/turret, and why they need to be accurately aligned15. The need to produce a balanced capstan/turret arrangement, with tools appropriately positioned around the

turret stations16. Factors which determine speeds and feeds to be used (material, type of tooling, depth of cut, workpiece

rigidity, machine condition, multiple cutting arrangements between capstan/turret and saddle, tolerance andfinish required)

17. How the various types of materials will affect the feeds and speeds that can be used18. The type of cutting fluids that are used, and precautions to be taken when handling and using them19. How to set up the turret lathe and its accessories for the particular operations being performed20. The need to conduct trial runs, and to check that the machine is set up and producing the components

correctly21. Problems that can occur with setting up the workholding devices, tooling and machine operating parameters,

and what to do if they occur22. The extent of your own responsibility and whom you should report to if you have problems that you cannot

resolve


263





required)evidence typedate apply activities during setting up (all)hold components securelytools are in suitable conditionapply safe working practicesensure correctly adjusted machine guards are in placeselect, mount and secure the workpiece (four)hand chucks with hard jawshand chucks with soft jawspower chucks with hard jawspower chucks with soft jawsjigs/fixturescollect chucksuse turning tool (two)solid high speed steelbrazed tungsten carbideindexible tipsselect, mount roughing and finishing tools (eight)turning toolsfacing toolsform toolschamfer/radiusparting off toolsthread chasersingle point threading boring barsrecessing toolscentre drillstwist/core drillssolid reamersexpanding reamerstapsdiesknurling toolsmount, secure and position tools (all)front tool boxpolygon/special profile boxesturret/capstan knee boxrear tool postending boxesboring bars (single/multiple)chucks/floating arrangementsdie boxesroller boxmultiple cutting arrangements






264


evidence typedate set up machine in accordance with instructions and specification (all)position of workpiece position of turning toolsscrew threading devicesworkpiece speed and feeddepth of cut (roughing/finishing)turret/saddle feed stops and indicatorscutting fluid flow rate machine guards/safety mechanismsset up machine to produce internal/external profiles (ten) flat facesparallel diametersstepped diameterstapered diametersdrilled holesbored holesreamed holesprofile formsinternal threadsexternal threadseccentric featuresparting offchamfers and radiiknurls/special finishesgrooves/undercutscounterboresmachine components from (one)ferrousnon-ferrousnon-metallicproduce trial components to prove machine is operating to specification (all)free from false tool cuts/burrs/sharp edgesdimensional tolerance equivalent to BS4500/BS1916 grade 7reamed/bored holes within h8screw threads BS medium fitangles within +/- 0.5 degreesurface finish 63µin or 1.6µm


Candidate: Date:

Assessor: Date:


265

Unit No 54: Setting Single-Spindle Automatic Turning Machines for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up single-spindle automatic turning machines for production, in accordance with approved procedures. This will involve selecting the appropriate workholding devices, securing them to the machine spindle, selecting and setting suitable chuck jaws, boring out soft jaws, and mounting workpieces in jigs or fixtures. You will be expected to select the appropriate turning tools, check that they are in a usable condition, and mount and secure them to the relevant tool holding devices, in front and rear tool posts and turret head.

You will need to set the machine operating parameters to produce the workpiece to the required specification. This will involve selecting, mounting and setting up turret and slide operating cams, cam timing, setting trip dogs, limit switches, stops, feed and speed mechanisms, setting appropriate depths of cut for roughing and finishing operations, and setting up multiple cutting arrangements between turret and slide. You must produce trial cuts and prove the machine is working satisfactorily before declaring the machine ready for production. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.

Your responsibilities will require you to comply with organisational policy and procedures for the machine setting activities undertaken, and to report any problems with the machine, tooling, equipment or setting-up activities that you cannot resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting-up procedures used. You will understand the machine used, and its application, and will know about the workholding devices, turning tools, relevant materials, consumables and setting up procedures, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the work output is to the required specification.




266

Unit No 54: Setting Single-Spindle Automatic Turning Machines for Production Performance statements:




● hold components securely without distortion● check cutting tools are in a suitable condition






4. Select and mount roughing and finishing tools, to include eight of the following types of tools:● turning tools● facing tools● form tools● chamfer/radius

● parting off tools● thread chaser● single point threading ● boring bars

● recessing tools● center drills ● twist/core drills● solid reamers


knurling tools5. Mount, secure and position tools in seven of the following devices:

front tool box rear tool post die boxes roller boxesvertically or tangentially in turret knee box boring bars (single and multiple)chucks or floating arrangements

to produce multiple cutting arrangementsspecial purpose profiling boxes (square, hexagon)

6. Set up machine in accordance with instructions and specifications, to include setting all of the following:● position of workpiece in workholding device● position of turning tools in relation to workpiece● selecting and setting appropriate cams

● depth of cut for roughing and finishing● machine guards/safety mechanisms● setting trip dogs and limit switches

● setting stops ● setting spindle speeds ● setting linear feed rate ● cutting fluid flow rate7. Set up the machine to produce internal and external profiles that include ten of the following:

● flat faces ● parallel diameters● stepped diameters● tapered diameters








267

Unit No 54: Setting Single-Spindle Automatic Turning Machines for Production Knowledge statements:


1. The specific safety precautions to be taken when setting up workholding devices and accessories, workpiece and turning tools on single spindle automatic turning machines

2. The hazards associated with automatic turning machines (moving parts of machinery, handling turning tools, handling cutting fluids, airborne particles, tool breakage, power chucks, insecure components, automatic operations), and how they can be minimised



clean and tidy6. The basic principles of operation of the single-spindle automatic turning machine and its accessories, and

typical operations that they can perform7. How to handle and store turning tools safely and correctly8. How to use and extract information from engineering drawings and related specifications, to include symbols

and conventions to appropriate BS or ISO tandards in relation to work undertaken9. How to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece

reference points and system of tolerancing10. Terminology used in single spindle automatic lathe turning in relation to the activities undertaken11. The range of work holding methods and devices that are used on single-spindle automatic lathes (two, three

and four jaw chucks, hand and power operated chucks, collet chucks, jigs and fixtures)12. The use of hard and soft jaws in chucks, and the methods of boring out soft jaws to suit the workpiece13. The different types of turning tools that are used, and how they are selected, prepared and mounted to the

machine tool holding devices (front tool box, rear tool box, turret head)14. The use of pilot bars and shoes for the turret, and why they need to be accurately aligned15. The need to produce a balanced turret arrangement, with tools appropriately positioned around the turret

stations16. The various specialist devices that can be used (such as die boxes, roller boxes, special purpose forming

boxes for flats, squares, hexagons etc)17. The selection of cams, and how they are set up and timed in order to produce the components to the required

specification18. Factors which determine speeds and feeds to be used (material, type of tooling, depth of cut, workpiece

rigidity, machine condition, multiple cutting arrangements between turret and slide, tolerance and finishrequired)

19. How the various types of materials will affect the feeds and speeds that can be used20. The type of cutting fluids that are used, and precautions to be taken when handling and using them21. How to set up the automatic lathe and its accessories for the particular operations being performed22. The need to conduct trial runs, and to check that the machine is set up and producing the components



resolve


268





required)evidence typedate apply activities during setting up (all)hold components securelycheck cutting tools are in suitable conditionapply safe working practicesensure correctly adjusted machine guards are in placeselect, mount and secure the workpiecehand chucks with hard jawshand chucks with soft jawspower chucks with hard jawspower chucks with soft jawsjigs/fixturescollet chucksuse turning tools (two)solid high speed steelbrazed tungsten carbideindexible tipsselect, mount roughing and finishing tools (eight)turning toolsfacing toolsform toolschamfer/radiusparting off toolsthread chasersingle point threading boring barsrecessing toolscentre drillstwist/core drillssolid reamersexpanding reamerstapsdiesknurling toolsmount, secure and position tools (seven)front tool boxvertically/tangentially in turret knee boxboring bars (single and multiple)chucks or floating arrangementsrear tool postdie boxesroller boxesproduce multiple cutting arrangementsspecial purpose profiling boxes






269


evidence typedate set up machine in accordance with instructions and specification (all)position of workpieceposition of turning toolsselect/set appropriate camssetting stopssetting spindle speedsdepth of cut roughing/finishingmachine guards/safety mechanismssetting trip dogs/limit switchessetting linear feed ratecutting fluid flow rateset up machine to produce internal/external profiles (ten) flat facesparallel diametersstepped diameterstapered diametersdrilled holesbored holesreamed holesprofile formsinternal threadsexternal threadseccentric featuresparting offchamfers and radiiknurls/special finishesgrooves/undercutscounterboresmachine components from (one)ferrousnon-ferrousnon-metallicmake trial components to prove machine is operating (all)components free from false tool cuts/burrs/sharp edgesdimensional tolerance equivalent to BS4500/BS1916 grade 7reamed/bored holes within H8screw threads BS medium fitangles within +/- 0.5 degreesurface finish 63µin or 1.6µm


Candidate: Date:

Assessor: Date:


270

Unit No 55: Setting Multi-Spindle Automatic Turning Machines for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up multi-spindle automatic turning machines for production, in accordance with approved procedures. This will involve selecting the appropriate workholding devices, securing them to the machine spindle, selecting and setting suitable collets or chuck jaws, boring out soft jaws (where applicable) and mounting workpieces in jigs or fixtures. You will be expected to select the appropriate turning tools, check that they are in a usable condition, and mount and secure them to the relevant tool holding devices, in front and rear tool posts, tangential slides and turret head.

You will need to set the machine operating parameters to produce the workpiece to the required specification. This will involve selecting, mounting and setting up turret and slide operating cams, cam timing, setting trip dogs, limit switches, stops, feed and speed mechanisms, setting appropriate depths of cut for roughing and finishing operations, and setting up multiple cutting arrangements between turret and slides. You must produce trial cuts and prove the machine is working satisfactorily before declaring the machine ready for production. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.

Your responsibilities will require you to comply with organisational policy and procedures for the machine setting activities undertaken, and to report any problems with the machine, tooling, equipment or setting-up activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting up procedures used. You will understand the multi-spindle machine used, and its application, and will know about the workholding devices, turning tools, relevant materials, consumables and setting up procedures, in adequate depth to provide a sound basis for setting up the equipment, correcting faults and ensuring the work output is produced to the required specification.




271

Unit No 55: Setting Multi-Spindle Automatic Turning Machines for Production Performance statements:



You must:

1. ● hold components securely without distortion ● check cutting tools are in suitable condition


2. Select, mount and secure the workpiece using two of the following workholding devices: ● power chucks with hard or soft jaws ● jigs/fixtures ● collet chucks


4. Select and mount roughing and finishing tools, to include eight of the following types of tools:● turning tools● facing tools● form tools● chamfer/radius

● parting off tools● thread chaser● single point threading ● boring bars

● recessing tools● center drills ● twist/core drills● solid reamers


knurling tools5. Mount, secure and position tools mounted in seven of the following devices:

front tool box rear tool post die boxes roller boxesvertically or tangentially in turret knee box boring bars (single and multiple)chucks or floating arrangements

to produce multiple cutting arrangementsspecial purpose profiling boxes (square, hexagon)tangential tool posts

6. Set up machine in accordance with instructions and specifications, to include setting all of the following:● setting stops ● setting spindle speeds ● setting linear feed rate ● cutting fluid flow rate● position of workpiece in work holding device● position of turning tools in relationship to workpiece● selecting and setting appropriate cams● bar feed and stop mechanisms

● depth of cut for roughing and finishing● machine guards/safety mechanisms● setting trip dogs and limit switches





8. Machine components made from one of the following types of material:● ferrous ● non-ferrous ● non-metallic




272

Unit No 55: Setting Multi-Spindle Automatic Turning Machines for Production Knowledge statements:


1. The specific safety precautions to be taken when setting up workholding devices and accessories, workpieceand turning tools on multi-spindle automatic turning machines

2. The hazards associated with automatic turning machines (moving parts of machinery, handling turning tools, handling cutting fluids, airborne particles, tool breakage, power chucks, insecure components, automatic

operations), and how they can be minimised3. How to start and stop the machine in normal and emergency situations4. The importance of ensuring the machine is isolated from the power supply before mounting turning tools and


clean and tidy6. The basic principles of operation of the multi-spindle automatic turning machine and its accessories, and

typical operations that they can perform7. How to handle and store turning tools safely and correctly8. How to use and extract information from engineering drawings and related specifications, to include symbols


reference points and system of tolerancing10. Terminology used in multi-spindle automatic lathe turning in relation to the activities undertaken11. The range of workholding methods and devices that are used on single spindle automatic lathes (two, three

and four jaw chucks, hand and power operated chucks, collet chucks, jigs and fixtures)12. The use of hard and soft jaws in chucks, and the methods of boring out soft jaws to suit the workpiece13. The different types of turning tools that are used, and how they are selected, prepared and mounted to the

machine tool holding devices (front tool box, rear tool box, tangential slides, turret head)14. The use of pilot bars and shoes for the turret, and why they need to be accurately aligned15. The need to produce a balanced turret arrangement, with tools appropriately positioned around the turret

stations16. The various specialist devices that can be used (such as die boxes, roller boxes, special purpose forming

boxes for flats, squares, hexagons etc)17. The selection of cams, and how they are set up and timed in order to produce the components to he required

specification18. Factors which determine speeds and feeds to be used (material, type of tooling, depth of cut, workpiece

rigidity, machine condition, multiple cutting arrangements between turret and slide, tolerance and finishrequired)

19. How the various types of materials will affect the feeds and speeds that can be used20. The type of cutting fluids that are used, and precautions to be taken when handling and using them21. How to set up the automatic lathe and its accessories for the particular operations being performed22. The need to conduct trial runs, and to check that the machine is set up and producing the components



resolve


273





required)evidence typedate apply activities during setting up (all)hold components securelycheck cutting tools are in suitable conditionapply safe working practicesensure correctly adjusted machine guards are in placeselect, mount and secure the workpiecepower chunks with hard/soft jawsjigs/fixturescollet chucksuse groups of turning tool (two)solid high-speed steelbrazed tungsten carbideindexible tipsselect, mount roughing and finishing tools (eight)turning toolsfacing toolsform toolschamfer/radiusparting off toolsthread chasersingle point threading boring barsrecessing toolscentre drillstwist/core drillssolid reamersexpanding reamerstapsdiesknurling toolsmount, secure and position tools (all)front tool boxvertically/tangentially turret knee boxboring bars (single and multiple)chucks or floating arrangementsrear tool postdie boxesproduce multiple cutting arrangementsspecial purpose profiling boxestargential tool postsroller boxes






274

required)evidence typedate set up machine in accordance with instructions and specification (all)setting stopsposition of workpiece position of turning toolsselection/setting appropriate camsbar feed and stop mechanismssetting spindle speedssetting linear feed ratecutting fluid flow ratedepth of cut for roughing/finishingmachine guards/safety mechanismssetting trip dogs/limit switchesset up machine to produce internal/external profiles (ten)flat facesparallel diametersstepped diameterstapered diametersdrilled holesbored holesreamed holesprofile formsinternal threadsexternal threadseccentric featuresparting offchamfers and radiiknurls/special finishesgrooves/undercutscounterboresmachine components from (one)ferrousnon-ferrousnon-metallicmake trial component materials to prove machine is operating to specification (all)components free from false tool cuts/ burrs/sharp edgesdimensional tolerance equivalent to BS4500/BS1916 grade 7reamed/bored holes within H8screw threads BS medium fitangles within +/- 0.5 degreesurface finish 63µin or 1.6µm


Candidate: Date:

Assessor: Date:

Unit No 56: Setting Single and Multi-Spindle Drilling Machines for Production


275

Unit No 56: Setting Single and Multi-Spindle Drilling Machines for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up single and multi-spindle drilling machines and associated drilling equipment, in accordance with approved procedures. This involves selecting the appropriate workholding devices, and mounting and positioning them to the machine in the correct location for the type of operation being carried out. You will also be expected to select the appropriate drills, reamers, counterbore and countersink tools, spot facing tools and taps, check them for defects, and mount and secure them to the relevant tool holding device.

You will set up and align the workpiece in the correct relationship to the machine spindle and set the machine operating parameters to produce the workpiece to the required specification. You must produce trial cuts and prove the machine is working satisfactorily before declaring the installation ready for production. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.

Your responsibilities will require you to comply with organisational policy and procedures for the machine setting activities undertaken, and to report any problems with the machine, work holding device, tools, equipment or setting up activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting-up procedures used. You will understand the single and multi-spindle drilling machine used, and their application, and will know about the workholding devices, tools, relevant materials, consumables and setting-up procedures, in adequate depth to provide a sound basis for setting up the equipment, correcting faults and ensuring work output is produced to the required specification.



276

Unit No 56: Setting Single and Multi-Spindle Drilling Machines for ProductionPerformance statements:




● ensure components are held securely without distortion ● check cutting tools are maintained in suitable condition● apply safe working practices at all times● ensure correctly adjusted machine guards are in place

2. Prepare a multi-spindle drilling machine and three of the following drilling machines: ● pedestal drill● bench drill

● radial arm drill● special purpose drill

3. Select, prepare and mount work holding device and workpiece, to include three of the following: ● drill jigs● machine vice

● chucks ● angle bracket

● vee block and clamps● clamping direct to machine table

● indexing device

4. Select and mount cutting tools, to include eight of the following: ● straight twist drills● straight core drills● taper drills

• counterbore tools• countersink tools● centre drills

• solid reamers• expanding reamers● taper reamers

• spot facing tools• taps• special tools

5. Set up the machine in accordance with instructions and specifications, to include setting all of the following: ● setting speeds and feeds ● cutting fluids ● tapping compounds● mounting workholding device and workpiece● setting workpiece in relation to machine spindle

● positioning drills/cutting tools ● setting drill/cutting tool depth

6. Set up the machine to produce the required hole, that must include all of the following: • drilling to depth• drilling through work piece

• drilling flat bottomed• counter boring

• countersinking• reaming

● spot facing● tapping


8. Make trial components to prove the machine is operating to required specification, to include all the following:● components to be free from false tool cuts, burrs and sharp edges● dimensional tolerance equivalent to BS 4500 or BS 1916 Grade 7● reamed and bored holes within H8● screw threads BS medium fit● angles within +/- 0.5 degree● surface finish 63µin or 1.6µm


277

Unit No 56: Setting Single and Multi-Spindle Drilling Machines for ProductionKnowledge statements


1. The specific safety precautions to be taken when setting up workholding devices, tools and cutters on singleand multi-spindle drilling machines

2. The hazards associated with single and multi-spindle drilling machines (moving parts of machinery, handlingtools and cutters, lifting and moving workpieces, flying swarf, tool breakage, insecure components), and howthey can be minimised

3. How to start and stop the machine in normal and emergency situations4. The importance of ensuring the machine is isolated from the power supply before mounting tools, workpieces

and workholding devices5. The importance of wearing the appropriate protective clothing and equipment, and of keeping the work area

clean and tidy6. The basic principles of operation of the single and multi-spindle drilling machines, and typical operations that

they can perform7. How to handle and store drills and cutters safely and correctly8. How to use and extract information from engineering drawings and related specifications, to include symbols


reference points and system of tolerancing10. Terminology used in single and multi-spindle drilling in relation to the activities undertaken11. The range of workholding methods and devices that are used on machines (drill jigs, vice, chucks, clamps, vee

blocks)12. The methods of mounting and setting the workpiece on/in the workholding device, and the tools and equipment

that can be used13. The different types of drills and cutters that are used, and how they are selected, prepared and mounted to the

machine tool holding devices14. Factors which determine speeds and feeds to be used (material, type of cutter/tool, workpiece rigidity, machine

condition, tolerance and finish required)15. How the various types of materials will affect the speeds and feeds that can be used16. The type of cutting fluids that are used, and precautions to be taken when handling and using them17. How to set up the machine for the particular operations being performed18. The need to conduct trial runs, and to check that the machine is set up and running safely and correctly19. Problems that can occur with setting up the single and multi-spindle drilling tools and cutters, work holding

devices and machine operating parameters, and what to do if they occur20. The extent of your own responsibility and whom you should report to if you have problems that you cannot

resolve


278





required)evidence typedate apply activities during setting up (all)ensure components are held securelycheck cutting tools are in suitable conditionapply safe working practicesensure correctly adjusted machine guards are in placeprepare a multi-spindle drilling machine/ other drilling machines (three)pedestal drillbench drillradial arm drillspecial purpose drillselect, prepare and mount workholding device and workpiece (three)drill jugsmachine vicechucksangle bracketvee block and clampsclamping direct to machine tableindexing deviceselect and mount cutting tools (eight)straight twist drillsstraight core drillstaper drills counter bore toolscounter sink toolscentre drillssolid reamersexpanding reamers taper reamersspot facing reamerstapsspecial formsset up machine according to instructions and specifications (all)setting speeds and feedsmounting workholding device and workpiecesetting workpiececutting fluidtapping compoundspositioning drills/cutting toolssetting drill/cutting tool depth


279





required)evidence typedate set up machine to produce required hole (all)drilling to depthdrilling through work piecedrilling flat bottomedcounter boringcountersinkingreamingspot facingtappingmachine components from (one)ferrousnon-ferrousnon-metallicmake trial components to prove machine is working (all)components free from false tool cuts/ burrs/sharp edgesdimensional tolerance equivalent to BS4500/BS1916 grade 7reamed/bored holes within H8screw threads BS medium fitangles within +/- 0.5 degreesurface finish 63µin or 1.6µm


Candidate: Date:

Assessor: Date:


280

Unit No 57: Setting Tool and Cutter Grinding Machines for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up tool and cutter grinding machines, and associated tool and cutter grinding equipment, in accordance with approved procedures. This involves selecting the appropriate workholding devices, and mounting and positioning them to the machine in the correct location for the type of operation being carried out. You will also be expected to select the appropriate grinding wheels and tools, check them for defects, and mount and secure them to the relevant holding device. You will set up and align the workpiece in the correct relationship to the grinding wheel, and set the machine operating parameters to grind the workpiece to the required specification.

The tools to be ground will include such things as drills, milling cutters, turning tools, saws, shaping and slotting tools, hobs, gear cutting and shaving tools, and broaches. You must produce trial cuts and prove the machine is working satisfactorily before declaring the machine ready for operation. Making adjustments to settings to achieve specification, and solving machine-related problems during operation, will also form part of your role.

Your responsibilities will require you to comply with organisational policy and procedures for the machine setting activities undertaken, and to report any problems with the machine, grinding wheels, equipment or setting-up activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting-up procedures used. You will understand the tool and cutter grinding machine used, and its application, and will know about the workholding devices, cutters, tools, relevant materials, consumables and setting up procedures, in adequate depth to provide a sound basis for setting up the equipment, correcting faults and ensuring the tools are ground to the required specification.



281

Unit No 57: Setting Tool and Cutter Grinding Machines for ProductionPerformance statements:




● hold components securely without damage ● ensure grinding wheels are in a suitable condition

● apply safe working practices at all times● correctly adjusted machine guards are in place

2. Prepare one of the following the tool and cutter grinding machines in readiness for production: • universal tool and cutter grinder • purpose-built tool and cutter grinder

3. Select, prepare and mount workholding devices to include five of the following: ● arbors ● centres ● chucks ● vices ● collets ● work heads ● work rests● ancillary equipment ● indexing mechanisms

4. Select and mount diamond wheels and grit wheels, to include all of the following: ● selecting grinding wheels for specific materials (diamond grade, grit grade, grain size, structure, bond)● mounting wheels (paper washers, flanges, locking pressure)● testing wheels for cracks/damage ● balancing wheels (where appropriate)

6. Prepare and dress grinding wheels using all of the following, as applicable to the machine used:● dressing and ‘trueing up’ grinding wheels● wheel forming (chamfers, radii, angular forms, profiles)

● relieving the wheel sides ● diamond dressing sticks

7. Set up the machine in accordance with instructions and specifications, to include setting all of the following: ● centres for tapers ● centres for parallelism ● setting indexing devices ● positioning wheels● workpiece position and alignment● setting dust extraction systems

● setting grinding depth/cut required● machine guards/safety mechanisms

8. Set up the machine to grind new and refurbished tools and cutters, to include ten the following: • twist drills• core drills

• reamers• end mills

• face mills• hobs

• lathe tools● form tools

● slot drills● slotting tools

● broaches● slab mills

● counterbore tools ● gear shaving ● machine saws ● side/face cutters9. Grind tools and cutters made from both of the following types of material:

● high-speed steel ● tungsten carbide10. Make trial runs to prove the machine is set up correctly and operating safely, to include checking all the following:

● all operations are carried out to the required specification● ground cutting angles and clearance meet operational requirements ● where applicable, dimensional accuracy and surface texture are within the tooling requirements


282

Unit No 57: Setting Tool and Cutter Grinding Machines for ProductionKnowledge statements


1. The specific safety precautions to be taken when setting up workholding devices, tools and cutters on a tooland cutter grinding machine

2. The legislation that governs the mounting, dressing and balancing of grinding wheels (eg, Abrasive Wheels Regulations), and how this applies to you

3. The hazards associated with tool and cutter grinding machines (moving parts of machinery, handling tools andcutters, lifting and moving workpieces, wheel breakage, insecure components, airborne particles, sparks andfire hazards), and how they can be minimised

4. How to start and stop the machine in normal and emergency situations5. The importance of ensuring the machine is isolated from the power supply before mounting grinding wheels,

workpieces and work holding devices6. The importance of wearing the appropriate protective clothing and equipment, and of keeping the work area

clean and tidy7. The basic principles of operation of the tool and cutter grinding machine, and typical operations that they can

perform8. How to handle and store tools and cutters safely and correctly9. How to handle and store grinding wheels safely and correctly10. How to use and extract information from engineering drawings and related specifications, to include symbols


reference points and system of tolerancing12. Terminology used in tool and cutter grinding in relation to the activities undertaken13. The range of workholding methods and devices that are used on tool and cutter grinding machines14. The methods of mounting and setting the workpiece on the workholding device, and the tools and equipment

that can be used15. The different types of tool and cutter grinding wheels and grits that are used, and how they are selected,

prepared and mounted to the machine tool holding devices16. How to check that the grinding wheels are in a safe and serviceable condition (free from damage, cracks,

correctly balanced)17. Methods of forming the wheels to the required profile (use of diamond dressing units, wheel forming

equipment)18. The need for ‘trueing up’ and dressing of wheels to prevent glazing and burning of the workpiece19. Factors which determine speeds to be used (material, type of grinding wheel, workpiece rigidity, machine

condition, tolerance and finish required)20. How the various types of materials will affect the speeds that can be used21. How to set up the machine for the particular operations being performed22. The need to conduct trial runs, and to check that the machine is set up and running safely and correctly23. Problems that can occur with setting up the tool and cutter grinding machine, workholding devices and

machine operating parameters, and what to do if they occur.24. The extent of your own responsibility and whom you should report to if you have problems that you cannot

resolve


283





required)evidence typedate apply activities during setting up (all)hold components securelyensure grinding wheels are in suitable conditionapply safe working practicescorrectly adjusted machine guards are in placeprepare tool and cutter grinding machines (one)universal tool cutter grindingpurpose-built tool and cutter grinderselect, prepare and mount workholding device (five)arborsancillary equipmentcentreschucksindexing mechanismsvicescolletswork headswork restsselect and mount diamond wheels and grit wheels (all)select grinding wheelsmounting wheelstesting wheelsbalancing wheelsprepare and dress grinding wheels (all)dressing and ‘trueing up’grinding wheelswheel formingrelieving the wheel sidesdiamond dressing sticksset up machine in accordance with instructions and specification (all)centres for taperscentres for parallelismsetting indexing devicepositioning wheelsworkpiece position/alignmentset dust extractionset grinding depth/cut machine guards/safety safety mechanisms


284





required)evidence typedate set up machine to grind new refurbished tools and cutters (ten)twist drillscore drillscounterbore toolsreamersend millsface millshobsgear shavinglathe toolsform toolsmachine sawsslot drillsslotting toolsside/face cuttersbroachesslab millsgrind tool and cutters material (both)high speed steeltungsten carbidetrial and check machine is set up correctly and operates safely (all)operation carried out to required specificationground cutting angles clearance meet requirementsdimensional accuracy/surface texture


Candidate: Date:

Assessor: Date:


285

Unit No 58: Setting Special-Purpose Machines for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up special-purpose machines for production, in accordance with approved procedures. This will involve selecting the appropriate workholding devices, securing them to the machine spindle, selecting and setting suitable collets or chuck jaws, boring out soft jaws (where applicable) and mounting workpieces in jigs or fixtures. You will be expected to select the appropriate tooling, to check that it is in a usable condition, and to mount and secure it to the relevant tool holding devices.

You will need to set the machine operating parameters to produce the workpiece to the required specification. This will involve selecting, mounting and setting up component loading mechanisms, operating cams, cam timing, and setting trip dogs, limit switches, stops, feed and speed mechanisms. You must produce trial runs and prove the machine is working satisfactorily before declaring the machine ready for production. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.

Your responsibilities will require you to comply with organisational policy and procedures for the machine setting activities undertaken, and to report any problems with the machine, tooling, equipment or setting-up activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting-up procedures used. You will understand the machine used, and its application, and will know about the workholding devices, tooling, relevant materials, consumables and setting up procedures, in adequate depth to provide a sound basis for setting-up the equipment, correcting faults and ensuring the work output is produced to the required specification.

You will understand the safety precautions required when working with the machine and its associated tools and equipment.You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

This unit does not cover NC/CNC activities, for which other units apply.


286

Unit No 58: Setting Special-Purpose Machines for Production Performance statements:




● ensure components are held securely without distortion● check that cutting tools are in a suitable condition● apply safe working practices at all times● ensure correctly adjusted machine guards are in place

2. Select, mount and secure the workpiece using two of the following workholding devices:● hand chucks● power chucks● jigs/fixtures

● collet chucks● mandrels/arbors● machine vices

● clamping direct to machine table● ancillary devices (centres, vee blocks, pots, angle plates, face plates, indexing/rotary device)

3. Use two of the following groups of tooling:● turning tools

drilling bitsmilling cuttersgrinding wheels

forming toolsother special-purpose tooling

4. Set up special-purpose operating control systems, to include four of the following devices:cams and mechanical actuatorspneumatic actuators hydraulic actuators

electro-mechanical actuatorsfeed fingersgravity feed mechanisms

air feed mechanisms● magazine component loading

5. Set up the machine in accordance with instructions and specifications, to include all of the following as appropriate: ● setting stops ● setting spindle speeds ● setting linear feed rate ● selecting cutting fluid● position of workpiece in work holding device● component feed and stop mechanisms● position of tooling relation to workpiece

● selecting and setting appropriate cams● setting trip dogs and limit switches● machine guards/safety mechanisms

6. Machine components made of one type of material from the following:● ferrous ● non-ferrous ● non-metallic

7. Make trial runs to prove the machine is set up correctly and operating safely, to include checking all the following: ● all operations are carried out to the specification● speed and feed settings are suitable for operations performed● dimensional accuracy is within the specification requirements


287

Unit No 58: Setting Special-Purpose Machines for Production Knowledge statements:


1. The specific safety precautions to be taken when setting up workholding devices and accessories, workpieceand turning tools on special-purpose automatic machines

2. The hazards associated with automatic machines (moving parts of machinery, handling tooling, handlingcutting fluids, airborne particles, tool breakage, power chucks, insecure components, automatic operations),and how they can be minimised

3. How to start and stop the machine in normal and emergency situations4. The importance of ensuring the machine is isolated from the power supply before mounting tooling and


clean and tidy6. The basic principles of operation of the special-purpose machine used and its accessories, and typical

operations that it can perform7. How to handle and store tooling safely and correctly8. How to use and extract information from engineering drawings and related specifications, to include symbols


reference points and system of tolerancing10. Terminology used in relationship to the special-purpose equipment used and the activities undertaken11. The range of workholding methods and devices that are used on the machine (such as chucks, hand and

power operated, collet chucks, jigs and fixtures)12. The different types of tooling that is used, and how it is selected, prepared and mounted to the machine tool

holding devices13. The various specialist devices that can be used for component feeding (such as feed fingers, gravity feed

mechanisms, air feed supplies and magazine loading arrangements)14. The selection of cams, and how they are set up and timed in order to produce the components to he required

specification15. Factors which determine speeds and feeds to be used (material, type of tooling, operations performed,

workpiece rigidity, machine condition, simultaneous multiple operations, tolerance and finish required)16. How the various types of materials will affect the feeds and speeds that can be used17. The type of cutting fluids that are used, and precautions to be taken when handling and using them 18. How to set up the special-purpose machine and its accessories for the particular operations being performed19. The need to conduct trial runs, and to check that the machine is set up and producing the components

correctly20. Problems that can occur with setting-up the workholding devices, tooling and machine operating parameters,


resolve


288





required)evidence typedate apply activities during setting up (all)ensure components are held securelycheck cutting tools are in suitable conditionapply safe working practicesensure correctly adjusted machine guards are in placeselect, mount and secure the workpiece (two)hand chuckspower chucksjigs/fixturesclamping direct to machine tableancillary devicescollet chucksmandrels/arborsmachine vicesuse groups of tooling (two)turning toolsdrilling bitsmilling cuttersgrinding wheelsforming toolsspecial purpose toolingset up special-purpose operating control systems (four)cams and mechanical actuatorspneumatic actuatorshydraulic actuatorselectro-mechanical actuatorsfeed fingersgravity feed mechanismsair feed mechanismmagazine component loadingset up machine in accordance with instructions and specifications (all)setting stopssetting spindle speedssetting linear feed rateselecting cutting fluidposition of workpiececomponent feed and stop mechanismsposition of toolingselecting/setting appropriate camssetting trip dogs/limit switchesmachine guards/safety mechanisms


289





required)evidence typedate machine components from material (one)ferrousnon-ferrousnon-metallictrial and check machine is set up correctly and operates safely (all)operations are carried out to specificationspeed/feed settings are suitabledimensional accuracy is within specification requirements


Candidate: Date:

Assessor: Date:


290

Unit No 59: Setting Power Presses for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up single and multi-action power presses and associated equipment, in accordance with approved procedures. This involves selecting the appropriate press tools, and mounting and positioning them to the machine in the correct location for the type of operation being carried out. You will also be expected to set up and align all associated equipment, which will include material positioning mechanisms, workpiece ejection mechanisms, and all machine safety devices and guards.

You will need to set up the machine operating parameters to produce the workpiece to the required specification. You must produce trial pressings and prove the machine is working satisfactorily before declaring the installation ready for production. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.

Your responsibilities will require you to comply with organisational policy and procedures for the machine setting activities undertaken, and to report any problems with the machine, press tools, equipment or setting-up activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting-up procedures used. You will understand the power press used, and its application, and will know about the workholding devices, press tools, relevant materials, consumables and setting-up procedures, in adequate depth to provide a sound basis for setting-up the equipment, correcting faults and ensuring the work produced meets the required specification.

You will understand the safety precautions required when working with power operated presses and their associated tools and equipment, and the safeguards necessary for undertaking the activities safely and correctly. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.


291

Unit No 59: Setting Power Presses for ProductionPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Confirm that the equipment is set up correctly and is ready for use c. Manipulate the machine controls safely and correctly in line with operational proceduresd. Produce components to the required specificatione. Carry out quality sampling checks at suitable intervalsf. Deal promptly and effectively with problems within your control and report those that cannot be solvedg. Shut down the equipment to a safe condition on conclusion of the machining activities


You must:1. Confirm that the equipment is safe to use and fit for purpose by carrying out all of the following checks:

the machine selected is appropriate for the operation being performed (tonnage, open height, stroke) the power press tool setters safety clutch lock, brakes, and emergency stop facilities operate correctly the machine guards and safety devices function correctlypress tools are undamaged and in a serviceable condition

● machine settings are suitable for the material thickness and operations to be performed2. Prepare and set up one of the following types of power press:

● single action ● multiple action

3. Select, prepare, mount and position press tools to the machine, to cover all of the following: ● preparing the press to receive the tooling● setting workpiece feed and ejection systems● positioning, aligning and securing press tools● ensuring correct clamping of materials● fitting and adjusting guards, interlocks and other safety mechanisms● setting up press operating parameters (stroke, stroke speed, material feed mechanisms)● carrying out tool tryouts of the complete cycle, using manual operation

4. Set up the press to carry out five of the following operations: ● blanking● piercing ● cropping/shearing● bending/forming● securing/assembling

● notching ● joggling● coiling/rolling● planishing/flattening

● raising of first draw● forming of second draw● compound operations● progression tool

● cupping● embossing● coining● other operations

5. Produce components in one of the following types of material: ● ferrous materials● non-ferrous materials● deep drawing steels

6. Produce pressed components which comply with all of the following quality and accuracy standards: dimensional accuracy is within the specification tolerancesthe form or sharpness of the profile conforms to best practice and/or specification, without deformation

or crackingthe components produced conform to specification without defects


292

Unit No 59: Setting Power Presses for ProductionKnowledge statements:


1. The relevant parts of the Power Press Regulations, and how they apply to you and the work you are undertaking

2. The specific safety precautions to be taken when working with single and multiple action power presses and press tooling

3. The hazards associated with working with power presses (moving parts of machinery, material handling, material ejection, automatic processes, lifting and handling press tooling, using faulty or badly maintained equipment), and how they can be minimised

4. The correct protective clothing and handling precautions to be taken when working with power pressesand press materials

5. The correct methods of lifting and moving press tooling, and the types of equipment used6. How to check that lifting equipment is within its current test dates7. How to obtain the necessary drawings and forming specifications8. How to use and extract information from engineering drawings and related specifications, to include


reference points and system of tolerancing10. The various types of power presses that are used, and typical applications11. How to prepare and set up the power press and its tooling for a range of different applications12. The types of press tools that are used for the various operations, and how they are secured and set to

the machine’s tool holding device13. The preparations that need to be carried out on the materials prior to using them14. The basic characteristics of the materials with regard to the pressing operations undertaken15. The need to take care of the press tools and equipment; how to recognise faulty or damaged press tools;

how bending and forming tools should be stored16. The problems that can occur with the bending and forming activities, and how they can be avoided17. The organisational quality control procedures that are used, and how to recognise defects in the

components that are produced18. How to make dimensional and forming inspection checks, and the tools and equipment that can be used19. Accuracy and limitations of processes20. The extent of your own responsibility and whom you should report to if you have problems that you

cannot resolve


293





required)evidence typedate confirm and check that equipment is safe/fit for purpose (all)machine selected is appropriate for operationpower press tool setters operates correctlymachine guards/safety devices function correctlypress tools are undamaged/ in serviceable conditionmachine settings suitableset up following types of power press (one)single actionmultiple actionselect, prepare, mount and position press tools to the machine (all)prepare press to receive toolingset workpiece feed/ejection systemposition, align and secure press toolsensure correct clamping of materialsfit and adjust guards/locks/ safety mechanismsset up press operating parameterscarry out tool tryoutsset up press to carry out operation (five)blankingpiercing cropping/shearingbending/formingsecuring/assemblingnotchingjogglingcoiling/rollingplanishing/flatteningraising of first drawforming of second drawcompound operationsprogression toolcuppingembossingcoiningother operationsproduce components from material (one)ferrous materialsnon-ferrous materialsdeep drawing steels


294





required)evidence typedate produce pressed components which comply with quality and accuracy standard (all)dimensional accuracy is within specification toleranceform/sharpness of profile confirms to best practice/ specificationcomponents produced conform to specification


Candidate: Date:

Assessor: Date:


295

Unit No 60: Producing Components using Hand Fitting Techniques

Unit Summary

This unit identifies the competencies you need to produce detail components using hand fitting techniques, in accordance with approved procedures. You will be required to select the appropriate equipment to use, based on the operations to be carried out and the accuracy required. In producing the components, you will be expected to use appropriate tools and equipment to mark out the material for a range of features to be produced, and then to use hand tools, portable power tools, shaping and fitting techniques that are appropriate to the type of material and operations being performed. These activities will include such things as hand sawing, band sawing, filing, drilling, chiselling, threading, scraping, lapping and off-hand grinding. The components produced will have features that include flat, square, parallel and angular faces, radii and curved profiles, drilled holes, internal and external threads, and sliding or mating parts.

Materials to be used will include ferrous, non-ferrous, non-metallic and composites, which may be in sheet form, bar sections (such as square/rectangular, round, hexagonal) or part-machined components.

Your responsibilities will require you to comply with organisational policy and procedures for the cutting and shaping activities undertaken, and to report any problems with the equipment, materials or activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying hand fitting procedures. You will understand the hand fitting techniques used, and their application, and will know about the tools, materials and equipment used, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and producing the components to the required specification.

You will understand the safety precautions required when using hand and power tools. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.


296

Unit No 60: Producing Components using Hand Fitting TechniquesPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow relevant specifications for the component to be produced c. Obtain the appropriate tools and equipment for the shaping operations and check they are in a safe and usable conditiond. Shape the materials using appropriate methods and techniquese. Check that all the required shaping operations have been completed to the required specificationf. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must:1. Carry out all the following activities during hand fitting:

● use the correct issue of procedures and quality documentation● check all cables, extension leads or air supply hoses are in a serviceable condition● return all tools and equipment to the correct location on completion of the fitting activities● check all tools are within calibration date● leave the work area in a safe condition

2. Mark out a range of material forms to include five from the following:forgingsmachined itemscastings

● round/cylindrical sections● bar stock items● flat or sheet materials

● channel sections● angle irons● joist sections

● irregular shaped items● assemblies● other specific items

3. Use marking out methods and techniques which include two of the following:● direct marking using instruments ● use of templates ● tracing/transfer methods

4. Use a range of marking out equipment to include all of the following:● rules/tapes● dividers/trammels

● scribers● punches

● scribing blocks● squares

● protractors● vernier instruments

5. Mark out wokpieces which include five of the following features:● datum/centre lines● square/rectangular profiles● angles/angular profiles

● circles● radial profiles● linear hole positions

● radial hole positions● allowances for bending● simple pattern development.

6. Use a range of hand fitting methods to include seven from the following:filingdrilling

off hand grinding● power sawing

● scraping● chiselling

● threads external● threads internal

● lapping● hand sawing

● tapping

7. Produce components which combine several features and cover eight from the following:● flat datum faces● chamfers and radii● curved profiles● reamed holes

● faces which are square to each other ● faces which are parallel to each other● drilled holes (through, to a depth)● counterbores, countersinks, or spot face

● internal threads● external threads● faces angled to each other● sliding or mating parts

8 Produce components within all of the following standards, as applicable to the process: ● surface finish 63µin or 1.6 µm ● screw threads to BS Medium fit

● reamed and bored holes within H8● flatness and squareness 0.001″ per inch or 0.025mm per 25mm

● dimensional tolerance equivalent to BS 4500 or BS 1916 Grade 99. Cut and shape two different types of material from the following:

● low carbon steel● high carbon steel

● stainless steel● aluminum

● brass/bronze● plastic/synthetic

● composite


297

Unit No 60: Producing Components using Hand Fitting TechniquesKnowledge statements:


1. The Health and Safety requirements, and safe working practices and procedures required for the hand fitting activities undertaken

2. The importance of wearing appropriate protective clothing and equipment, and of keeping the work area safe and tidy

3. The hazards associated with the hand fitting techniques (use of power tools, trailing leads or hoses, damaged or badly maintained tools and equipment, using files with damaged or poor fitting handles), and how they can be minimised

4. The procedure for obtaining the required drawings, job instructions and other related specifications5. How to use and extract information from engineering drawings and related specifications, to include


reference points and system of tolerancing7. How to prepare the materials in readiness for the marking out activities, in order to enhance clarity,

accuracy and safety (visually checking for defects, cleaning the materials, removing burrs and sharp edges, applying a marking out medium)

8. How to select and establish suitable datums9. The importance of ensuring that marking out is undertaken from the selected datums, and the possible

effects of working from different datums10. Methods of holding and supporting workpieces during the marking out activities, and equipment that can

be used (surface plates, angle plates, vee blocks and clamps parallel bars, screw jacks) 11. Use of marking out conventions when marking out the workpiece (including datums, cutting guidelines,

square and rectangular profiles, circular and radial profiles, angles, holes which are linearly positioned, boxed and on pitch circles)

12. Ways of laying out the marking out shapes or patterns to maximise use of materials13. Setting and adjusting tools, such as squares, protractors and verniers14. The importance of using tools only for the purpose intended; the care that is required when using the

equipment and tools; the proper way of storing tools and equipment between operations15. The need for clear and dimensional accuracy in marking out to specification and drawing requirements16. The cutting and shaping methods that need to be used, and the sequence in which the operations will

need to be carried out17. How to file flat, square and curved surfaces and achieve a smooth surface finish18. How to cut external threads using hand dies, and the method of fixing and adjusting the dies to give the

correct thread fit19. How to determine the drill size for tapped holes, and the importance of using the taps in the correct

sequence20. How to produce a sliding or mating fit using filing, scraping and lapping techniques21. How to select saw blades for different materials, and how to set the saw blades for different operations,

such as cutting externally and internally22. The various types of files that are available, and the cut of files for different applications23. How to prepare the components for the filing operations (cleaning, de-burring, marking out)24. The use of vice jaw plates to protect the workpiece from damage25. The types and application of portable power tools that can be used for the hand fitting operations26. The importance of ensuring file handles are secure and free from embedded foreign bodies or splits27. How to check that portable power tools and extension cables are free from damage and in a safe usable

condition28. The problems that can occur with the cutting and shaping operations, and how can these be overcome29. The extent of your own responsibility and whom you should report to if you have problems that you

cannot resolve


298





required)evidence typedate apply activities during hand fitting (all)use correct issue of procedures/quality document check cables/extension leads /air supply hosestools/equipment to be returned to correct locationcheck tools are within calibration dateleave work area in safe conditionmark out a range of material forms to include (five)forgingsmachined itemscastings round/cylindrical sectionsbar stock itemsflat or sheet materialschannel sections angle ironsjoist sectionsirregular shaped itemsassembliesother specific itemsuse marking out methods and techniques (two)direct marking using instrumentsuse of templatestracing/transfer methodsuse a range of marking out equipment (all)rules/tapesdividers/trammelsscriberspunchesscribing blockssquaresprotractorsvernier instrumentsmark out workpiece featuring (five)datum/centre linessquare/rectangular profilesangles/angular profilescirclesradial profileslinear hole positionsradial hole positionsallowances for bendingsimple pattern development


299





required)evidence typedate use a range of hand fitting methods (eight)filingdrillingoff hand grindingpower sawingscrapingchisellingthreads externalthreads internallappinghand sawingtappingproduce components combine several features (nine)flat datum faceschamfers and radiicurved profilesreamed holesfaces which are square to each otherfaces which are parallel to each otherdrilled holescounterbores/countersinks/spot faceinternal threadsexternal threadsfaces angled to each othersliding or mating partsproduce components within standards (all)surface finish 63µin or 1.6µmscrew threads to BS medium fitdimensional tolerance equivalent to BS4500/BS1916 grade 9reamed and bored holes H8flatness/squareness 0.001” per 0.025mm per 25mmcut and shape different materials (two)low carbon steel high carbon steelstainless steelaluminumbrass/bronzeplastic/syntheticcomposite


Candidate: Date:

Assessor: Date:


300

Unit No 61: Assembling Mechanical Products

Unit Summary

This unit identifies the competencies you need to carry out assembly operations to produce mechanical assemblies, in accordance with approved procedures. You will be required to prepare the work area, and ensure it is safe and free from hazards. You will also be required to check the specified components are available and fit for purpose, to obtain all relevant and current documentation, to obtain the tools and equipment required for the assembly operations, and to check that they are in a safe and usable condition. In carrying out the assembly operations, you will be required to follow company procedures and specified assembly techniques, in order to assemble the mechanical product.

The assembly activities will also include making all necessary checks and adjustments, to ensure the components are correctly orientated, positioned and aligned, that moving parts have the correct working clearances, all fasteners are tightened to the correct torque, and that the assembled parts are checked for completeness and function as per the specification.

Your responsibilities will require you to comply with organisational policy and procedures for the assembly activities undertaken, and to report any problems with the assembly activities, materials or equipment that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying the assembly techniques and procedures. You will understand the mechanical product being assembled, and its application, and will know about the equipment, relevant components and joining techniques, in adequate depth to provide a sound basis for carrying out the activities to the required specification.

You will understand the safety precautions required when carrying out the assembly activities. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.


301

Unit No 61: Assembling Mechanical ProductsPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the relevant instructions, assembly drawings and any other specificationsc. Ensure that the specified components are available and that they are in a usable conditiond. Use the appropriate methods and techniques to assemble the components in their correct positionse. Secure the components using the specified connectors and securing devicesf. Check the completed assembly to ensure that all operations have been completed and the finished assembly meets

the required specificationg. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must:1. Carry out all the following during the assembly activities:

● use the correct issue of drawings, job instructions and procedures● check calibration dates of tools and measuring instruments to be used● use lifting and slinging equipment in accordance with health and safety guidelines and procedures● ensure the components and pipes used are free from foreign objects, dirt or other contamination● use relevant COSHH sheets and risk assessments● leave the work area in a safe condition

2. Produce assemblies using four of the following methods and techniques: ● assembling of components by expansion/contraction● fitting (eg, filing, scraping, lapping or polishing) ● securing using mechanical fasteners/threaded devices

● applying sealants/adhesives● electrical bonding of components● assembling of products by pressure

● setting working clearances ● drilling ● reaming ● balancing components● applying bolt locking methods ● shimming and packing ● blue-bedding of components● aligning components● riveting

● torque setting ● soldering/brazing ● fusion (non-critical joints)

3. Assemble products to meet the required specification, using at least seven of the following components: ● assembly structure (framework, support, casings, panels) ● fabricated components ● pre-machined components ● levers/linkages ● pipework/hoses ● cams and followers● bearings● seals

● bushes● gaskets

● shafts● chains

● couplings● sprockets

● keys● pulleys

● gears● springs

● belts ● other

4 Assemble products using two of the following assembly aids and equipment: ● workholding devices ● lifting and moving equipment ● specialised assembly tools/equipment ● jigs and fixtures ● shims and packing ● rollers or wedges ● supporting equipment

5. Carry out the required quality checks, to include eight from the following, using appropriate equipment: ● positional accuracy ● freedom of movement ● component security ● completeness● dimensions ● orientation ● alignment ● function ● bearing end float● operating/ working clearances ● free from damage or foreign objects

6. Produce mechanical assemblies which comply with one of the following quality and accuracy standards:● BS or ISO standards and procedures● customer standards and requirements ● company standards and procedures● specific system requirements


302

Unit No 61: Assembling Mechanical ProductsKnowledge statements:


1. The specific safety precautions to be taken whilst carrying out the mechanical assembly, including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials

2. The health and safety requirements of the work area in which you are carrying out the assembly activities, and the responsibility these requirements place on you

3. COSHH Regulations with regard to the substances used in the assembly process4. The hazards associated with producing mechanical assemblies, and how they can be minimised5. The personal protective equipment and clothing that needs to be worn during the assembly activities6. How to use and extract information from engineering drawings and related specifications, to include


reference points and system of tolerancing8. The general principles of mechanical assembly, and the purpose and function of the components and

materials used, including component identification systems (eg, codes and component orientation indicators)

9. Preparations that need to be undertaken on the components prior to fitting them into the assembly10. The assembly/joining methods, techniques and procedures to be used, and the importance of adhering

to these procedures11. How the components are to be aligned, adjusted and positioned prior to securing, and the tools and

equipment that is used12. The importance of using the specified components and joining devices for the assembly, and why you

must not use substitutes13. Where appropriate, the application of sealants and adhesives within the assembly activities, and the

precautions that must be taken when working with them14. The quality control procedures that need to be followed during the assembly operations15. How to conduct any necessary checks to ensure the accuracy, position, security, function and

completeness of the assembly16. How to detect assembly defects, and what to do to rectify them (ineffective joining techniques, foreign

objects, component damage)17. The methods and equipment used to transport, lift and handle components and assemblies18. How to check that the tools and equipment to be used are correctly calibrated and are in a safe and

serviceable condition19. The importance of ensuring that all tools are used correctly and within their permitted operating range20. The importance of ensuring all tools, equipment and components are accounted for and returned to their

correct location on completion of the assembly activities 21. Problems with the assembly operations, and the importance of informing appropriate people of non-

conformances22. The extent of your own responsibility and whom you should report to if you have problems that you

cannot resolve


303





required)evidence typedate activities during hand fitting (all)use correct issue of drawings /job instructions/procedures check calibration dates of tools/measuring instrumentsuse lifting/slinging equipment according to health & safety guidelines/proceduresensure components are free from foreign objects/dirt/other contamination use relevant COSHH sheets /risk assessmentsleave work area in safe conditionproduce assemblies using methods and techniques (four)assembling of components by expansion/contractionfittingsecuring using mechanical fasteners/threaded devicessetting working clearancesapplying bolt locking methodsaligning componentsrivetingdrillingshimming and packagingtorque settingsoldering/brazingapplying sealants/adhesiveselectrical bonding of componentsassembling of productsbalancing componentsblue-bedding componentsfusion (non critical joints)






304


evidence typedate assemble products to meet the required specification (seven)assembly structurepre-machined componentsbearingssealsbushesgasketslevers/linkagesshaftschainscouplingssprocketsfabricated componentspipework/hoseskeyspulleyscams and followersgears springsbeltsotherassemble products using aids and equipment (two)workholding devicesjigs and fixtureslifting and moving equipmentshims and packingspecialised assembly tools /equipment rollers or wedgessupporting equipmentusing appropriate equipment, carry out quality checks (eight)positional accuracy dimensionsoperating/working clearancesfreedom of movementorientationalignmentfree from damage/foreign objectscomponent securityfunctioncompletenessbearing end floatproduce mechanical assemblies to quality and accuracy standards (one)BS/ISO standards/procedurescustomer standards and requirementscompany standards and proceduresspecific system requirements


Candidate: Date:

Assessor: Date:

Unit No 62: Producing Components by Manual Machining


305

Unit No 62: Producing Components by Manual Machining

Unit Summary

This unit identifies the competencies you need to produce components using manual machining techniques, such as milling, turning, grinding, shaping/slotting, drilling/boring and spark/wire erosion, in accordance with approved procedures. You will be expected to produce components that require you to use a range of different machines, and this will involve setting-up the workholding arrangements, workpiece and machine tooling. The workpieces produced will have a combination of features, such as diameters, lengths, threads, flat faces, square faces, slots, profiles or special forms.

Your responsibilities will require you to comply with organisational policy and procedures for the machining activitiesundertaken, and to report any problems with the machines, tooling, materials or activities that you cannot personally resolve, or are outside your personal responsibilities, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying machining procedures and instructions. You will understand the machining processes, and their application, and will know about the machine, tooling, ancillary equipment, materials and consumables, in adequate depth to provide a sound basis for carrying out the machining activities, correcting faults and producing the components to the required specification.


This unit does not cover using NC/CNC equipment, for which other units apply.


306

Unit No 62: Producing Components by Manual MachiningPerformance statements:



You must:1 Carry out all the following activities during the machining activities:

● use the correct issue of drawings, specifications and quality documentation● check the machines used are in a safe and usable condition● check that cutting tools and equipment are in a serviceable condition● ensure that workpieces are held securely without distortion● apply safe and appropriate machining techniques at all times● use correctly adjusted machine guards and safety devices

2. Produce machined components using three of the following machining processes: • turning• drilling

• milling• spark/wire erosion

• grinding• shaping or slotting

3. Use a range of workholding devices, to include five of the following:● 3 jaw chucks● 4 jaw chucks● machine vices● vee blocks

● clamping arrangements● angle plates● magnetic plates● indexing devices

● face plates● special fixtures● collet chucks

4. Produce machined components which cover seven of the following features:● external diameters● internal diameters● lengths/depths● flat faces● parallel faces

● threads● circular/curved/radial profiles● faces that are square to each other● angular/tapered surfaces● steps/shoulders

● slots/recesses● drilled/bored/reamed holes● concave or convex forms● special forms

5. Produce components within all of the following standards, as applicable to the operation:● dimensional tolerance equivalent to BS 4500 or BS 1916 Grade 7● flatness and squareness 0.001″ per inch or 0.025mm per 25mm● reamed and bored holes within H8● surface finish 63 µin or 1.6 µµm

6. Machine three different types of material from: ● low carbon steel● high carbon steel

● stainless steel● cast iron

● aluminium● composite

● plastic/synthetic● special steels or alloys

● brass● bronze

7. Carry out the necessary checks during manufacture, for accuracy of at least five of the following: ● dimensions● angles

● flatness/squareness● concentricity

● thread size and fit● hole size/fit

● profile● quality of surface finish


307

Unit No 62: Producing Components by Manual MachiningKnowledge statements:


1. The safe working practices and procedures to be followed while operating machinery2. The safety mechanisms on the machine, and the procedure for checking that they are operating

correctly3. How to operate all the machine controls in both hand and power modes, and how to stop the machine in

case of an emergency4. The importance of wearing appropriate protective clothing and equipment, and of keeping the work area

clean and tidy5. Where to obtain the component drawings, specifications and/or job instructions required for the

components to be machined6. How to use and extract information from engineering drawings and related specifications, to include

symbols and conventions to appropriate BS or ISO standards in relation to work undertaken 7. How to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece

reference points and system of tolerancing8. The basic concepts of material removal using machines (such as lathes, milling, grinding, drilling,

shaping, slotting and electro discharge machining)9. The various machining techniques that can be used to produce the required shapes, and the types of

tooling and cutters required (including high-speed steel tools, solid carbide tools and interchangeable tipped tooling)

10. Types and applications of grinding wheels; methods of mounting; and why some wheels require balancing

11. Types and application of electrodes, wires and tapes used in spark and wire erosion activities12. The methods that can be used to position the workpiece in relation to the cutting tools13. The effects of backlash in the machine slides and how this can be overcome14. How to handle and store cutters, grinding wheels and tools, safely and correctly15. Factors which effect the selection of cutting feeds and speeds, the application of roughing and finishing

cuts and the depth of cut that can be taken (workpiece rigidity, machine condition, type of tooling being used, material type, finish and tolerance required)

16. How the various types of materials will affect the feeds and speeds that can be used17. The application of cutting fluids and dielectrics with regard to a range of different materials18. The effects of clamping the workpiece, and how material removal can cause warping/distortion in the

finished workpiece19. The quality control procedures used, inspection checks that need to be carried out, and the equipment

that will need to be used20. The problems that can occur with the machining activities, and how these can be overcome21. The extent of your own responsibility and whom you should report to if you have problems that you

cannot resolve


308





required)evidence typedate apply during machining activities (all)correct issue of drawings /specification/quality documentationcheck machines are safe /usablecheck cutting tools /equipment are in serviceable conditionensure workpieces are held securelyapply safe/appropriate machining techniquesuse correctly adjusted machine guards/safety devicesproduce machined components using (three)turningdrillingmillingspark/wire erosiongrindingshaping/slottinguse a range of workholding devices (five)3 jaw chucks4 jaw chucksmachine vicesvee blocksclamping arrangementsangle platesmagnetic platesindexing devicesface platesspecial fixturescollet chucksproduce machined components using (seven)external diametersinternal diameterslengths/depthsflat facesparallel facesthreadscircular/curved/radial profilesfaces that are square to each otherangular/tapered surfacessteps/shouldersslots/recessesdrilled/bored/reamed holesconcave or convex formsspecial forms






309


evidence typedate produce components to standards, as applicable to operation (all)dimensional tolerance equivalent to BS4500/BS1916 grade 7flatness/squareness 0.001” per 0.025mm per 25mmreamed and bored holes H8surface finish 63µin or 1.6µmmachine different types of material (three)low carbon steelhigh carbon steelstainless steelcast ironaluminiumcompositeplastic/syntheticspecial steels or alloysbrassbronzeapply accuracy checks during manufacture (five)dimensionsanglesflatness/squarenessconcentricity thread size and fithole size/fitprofilequality or surface finish


Candidate: Date:

Assessor: Date:


310

Unit No 63: Fitting Fluid Power Components to Mechanical Assemblies

Unit Summary

This unit identifies the competencies you need to assemble and fit fluid power equipment (pneumatic, hydraulic, or vacuum) to mechanical assemblies, in accordance with approved procedures. You will be required to prepare the work area, ensuring it is safe and free from hazards, check the specified components are available and fit for purpose, obtain all relevant and current documentation, and to obtain the tools and equipment required for the assembly operations, checking that they are in a safe and usable condition. In carrying out the fitting and assembly operations, you will be required to follow company procedures and specified assembly techniques, in order to assemble the mechanical product.

The assembly activities will also include making all necessary checks and adjustments to ensure the fluid power components are correctly positioned, aligned, dimensionally accurate and secure; pipework is dimensionally accurate and free from ripples, creases and damage; joints are checked for security, with threaded devices tightened correctly; electrical components are checked for safety, position, security and continuity; and test procedures (leak or pressure) are carried out to confirm that the fluid power assembly meets the operational performance required.

Your responsibilities will require you to comply with organisational policy and procedures for the assembly activities undertaken, and to report any problems with the assembly activities, materials or equipment that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to ensure that all tools, equipment and materials used in the assembly are correctly accounted for on completion of the activities, and to complete all necessary job/task documentation accurately and legibly. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying fluid power assembly techniques and procedures. You will understand the mechanical product being assembled, and its application, and will know about the equipment, relevant components and joining techniques, in adequate depth to provide a sound basis for carrying out the activities to the required specification.



311

Unit No 63: Fitting Fluid Power Components to Mechanical AssembliesPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the relevant instructions, assembly drawings and any other specificationsc. Ensure that the specified components are available and that they are in a usable conditiond. Use the appropriate methods and techniques to assemble the components in their correct positionse. Secure the components using the specified connectors and securing devicesf. Check the completed assembly to ensure that all operations have been completed and the finished assembly meets the required specificationg. Deal promptly and effectively with problems within your control and report those that cannot be solved



● use the correct issue of drawings, job instructions and specifications● check calibration dates of tools and measuring instruments to be used● ensure the components and pipes used are free from foreign objects, dirt or other contamination● apply safe and appropriate fitting and assembly techniques● use lifting and slinging equipment in accordance with health and safety guidelines and procedures● leave the work area in a safe condition

2. Assemble and fit one of the following types of fluid power systems: ● pneumatic● hydraulic

● vacuum● electro fluid power systems

3 Prepare, assemble and fit seven of the following components and materials: ● rigid pipe● flexible pipe● couplings ● intensifiers● valves

● compressors● regulators ● manifolds ● sensors● accumulators

● gauges/indicators ● clips / supports● lubricators ● heaters/driers ● coolers units

● cables and wires ● seals/gaskets ● locking wire● actuators/cylinders● separation units

● pumps● meters● filters ● motors● other

● reservoirs/storage devices ● electrical/electronic control systems

4. Carry out the quality checks using appropriate equipment, to include eight from: ● dimensions● positional accuracy● alignment

● correct direction and flow● leak or pressure tests● component security

● electrical continuity● completeness● function

● pipework (free from ripple and creases)5. Produce fluid power assemblies which comply with one of the following quality and accuracy standards:

● BS or ISO standards and procedures● customer standards and requirements ● company standards and procedures● specific system requirements


312

Unit No 63: Fitting Fluid Power Components to Mechanical AssembliesKnowledge statements:


1. The specific safety precautions to be taken while carrying out the fluid power assembly, including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials


3. COSHH Regulations with regard to the substances used in the assembly process4. The hazards associated with producing fluid power assemblies (pressurising and purging of circuits),

and how they can be minimised5. The personal protective equipment and clothing that needs to be worn during the assembly activities6. How to use and extract information from engineering drawings and related specifications, to include


reference points and system of tolerancing8. How to extract the necessary information from data supplied in order to complete fluid power assemblies9. The general principles of fluid power, and the purpose and function of the components and materials

used10. Preparations that need to be undertaken on the components prior to fitting them onto the assembly11. The fitting and assembly methods and procedures to be used, and the importance of adhering to these

procedures12. How the components are to be aligned, adjusted and positioned prior to securing, and the tools and

equipment that are used13. The importance of using the specified components for the assembly, and why you must not use

substitutes14. The specific methods used for leak detection, and when they should be applied15. How to conduct any necessary checks to ensure the safety, accuracy, position, security, function and

completeness of the assembly16. How to detect assembly defects/faults, and what to do to rectify them (ineffective joining techniques,

foreign objects, component damage)17. The methods and equipment used to transport, lift and handle components and assemblies 18. How to check that the tools and equipment to be used are correctly calibrated and are in a safe and

serviceable condition19. The importance of ensuring that all tools are used correctly and within their permitted operating range 20. The importance of ensuring all tools, equipment and components are accounted for and returned to their

correct location on completion of the assembly activities21. Problems with the assembly operations, and the importance of informing appropriate people of non-

conformances22. The extent of your own responsibility and whom you should report to if you have problems that you

cannot resolve


313





required)evidence typedate carry out during assembly activities (all)use correct issue of drawings /job instructions/ specificationscheck calibration dates of tools/measuring instrumentsensure components/pipes are free from foreign objects/ dirt or other contaminationapply safe/appropriate fitting /assembly techniquesuse lifting/slinging equipment according to health/safety guidelines/proceduresleave work in safe conditionassemble and fit fluid power systems (one)pneumatichydraulicvacuumelectro fluid power systemsprepare, assemble and fit components and materials (seven)rigid pipeflexible pipecouplingsintensifiersvalvesreservoirs/storage deviceselectrical/electronic control systemscompressorsregulatorsmanifoldssensorsaccumulatorsgauges/indicatorsclips/supportslubricatorsheaters/drierscooler unitscables and wiresseals/gasketslocking wireactuators/cylindersseparation unitspumpsmetersfiltersmotorsother


314





required)evidence typedate carry out quality checks using appropriate equipment (eight)dimensionspositional accuracyalignmentpipeworkcorrect direction and flowleak or pressure testscomponent securityelectrical continuitycompletenessfunctionfluid power assemblies quality and accuracy standard (eight)BS/ISO standards and procedurescustomer standards and requirementscompany standards and proceduresspecific system requirements


Candidate: Date:

Assessor: Date:


315

Unit No 64: Fitting Pipework Systems to Mechanical Assemblies

Unit Summary

This unit identifies the competencies you need to assemble and fit pipework systems to mechanical assemblies, in accordance with approved procedures. You will be required to prepare the work area, ensuring it is safe and free from hazards, to check the specified components are available and fit for purpose, to obtain all relevant and current documentation, and to obtain the tools and equipment required for the assembly operations, checking that they are in a safe and usable condition. In carrying out the assembly operations, you will be required to follow company procedures and specified assembly techniques, in order to assemble the pipework and components and to fit them to the mechanical assembly.

The assembly activities will also include making all necessary checks and adjustments to ensure that the pipework, when fitted to the assembly, is dimensionally accurate, is positioned and aligned correctly, is free from ripple, creases and damage, and that joints are correctly secured and checked for leaks using the appropriate equipment and procedures. The assembled pipework must be checked for completeness and that it functions as per the specification.

Your responsibilities will require you to comply with organisational policy and procedures for the assembly activities undertaken, and to report any problems with the assembly activities, materials or equipment that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to ensure that all tools, equipment and materials used in the assembly are correctly accounted for on completion of the activities, and to complete all necessary job/task documentation accurately and legibly. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying pipework fitting and assembly techniques and procedures. You will understand the mechanical product being assembled, and its application, and will know about the equipment, relevant components and joining techniques, in adequate depth to provide a sound basis for carrying out the activities to the required specification.



316

Unit No 64: Fitting Pipework Systems to Mechanical AssembliesPerformance statements:




● use the correct issue of drawings, job instructions and specifications● check calibration dates of tools and measuring instruments to be used● ensure the components and pipes used are free from foreign objects, dirt or other contamination● apply safe and appropriate fitting and assembly techniques at all times● use lifting and slinging equipment in accordance with health and safety guidelines and procedures● leave the work area in a safe condition

2. Assemble pipework systems using two of the following types of pipe: • steel pipe• copper pipe

• plastic pipe• flexible hoses

3. Produce pipework assemblies using two of the following methods: ● compression● bolting

● screwing● brazing

● push fit● soldering

● cementing/bonding

4. Assemble pipework systems using five of the following components: ● straight connectors● reduction pieces ● straight sections

● tee pieces● flanges ● elbows

● curved/profiled sections● pipe supports and clips ● couplings

● gaskets/seals● angular sections● other

5. Carry out all the following quality checks using appropriate equipment, to include:● dimensions● alignment● completeness● function● positional accuracy

● correct direction and flow● component security● component quality (free from ripple, creases)● leak or pressure tests

6. Produce pipework assemblies which comply with one of the following quality and accuracy standards: ● BS or ISO standards and procedures● customer standards and requirements ● company standards and procedures● specific system requirements


317

Unit No 64: Fitting Pipework Systems to Mechanical AssembliesKnowledge statements:


1. The specific safety precautions to be taken while carrying out the fitting of pipework systems to mechanical assemblies, including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials


3. COSHH Regulations with regard to the substances used in the assembly process4. The hazards associated with producing mechanical assemblies, and how they can be minimised5. The personal protective equipment and clothing that needs to be worn during the assembly activities6. How to use and extract information from engineering drawings and related specifications, to include


reference points and system of tolerancing8. How to extract the necessary information in order to produce pipework assemblies9. The general principles of producing pipework assemblies, and the purpose and function of the

components and materials used (including identification systems, eg colour codes)10. The application of different pipework assembly methods and techniques11. Preparations that need to be undertaken on the pipework prior to fitting them to the assembly12. The pipework assembly/joining methods and procedures to be used, and the importance of adhering to

these procedures. 13. How pipework is formed, aligned, adjusted and positioned prior to joining, and the tools and equipment

that are used14. The importance of using the specified pipework and fittings for the assembly, and why you must not use

substitutes15. The tests that can be applied to ensure the pipework assembly is safe and leak free16. The quality control procedures that need to be followed during the assembly operations17. How to conduct any necessary checks to ensure the safety, accuracy, position, security, function and

completeness of the pipework assembly18. How to identify pipework assembly defects, and what to do to rectify them (ineffective joining techniques,

component damage)19. How to check that the tools and equipment to be used are correctly calibrated and are in a safe and

serviceable condition20. The importance of ensuring that all tools are used correctly and within their permitted operating range21. The importance of ensuring all tools, equipment and components are accounted for and returned to their

correct location on completion of the assembly activities22. Problems with the assembly operations, and the importance of informing appropriate people of non-

conformances23. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


318





required)evidence typedate carry out during assembly activities (all)correct issue of drawings/job instructions/specificationscheck calibration dates of tools/measuring instrumentsensure components/pipes are free from foreign objects/ dirt/other contaminationapply safe/appropriate fitting /assembly techniquesuse lifting/slinging equipment in accordance with health/ safety guidelines/proceduresleave work in safe conditionassemble pipework systems from (two)steel pipecopper pipeplastic pipeflexible hosesproduce pipework assemblies using (two) compressionboltingscrewingbrazingpush fitsolderingcementing/bondingassemble pipework systems using (five)straight connectorsreduction piecesstraight sectionstee pieces flangeselbowscurved/profiles sectionspipe supports and clipscouplingsgaskets/sealsangular sectionsothercarry out quality checks using appropriate equipment (all)dimensionsalignmentcompletenessfunctionpositional accuracycorrect distortion and flow component securitycomponent qualityleak or pressure tests


319





required)evidence typedate produce pipework assemblies to quality and accuracy standards (one)BS/ISO standards and procedurescustomer standards and requirementscompany standards and proceduresspecific system requirements


Candidate: Date:

Assessor: Date:


320

Unit No 65: Fitting Electrical and Electronic Components to Mechanical Assemblies

Unit Summary

This unit identifies the competencies you need to assemble and fit electrical and electronic components to mechanical assemblies, in accordance with approved procedures. You will be required to prepare the work area, ensuring it is safe and free from hazards, to check the specified components are available and fit for purpose, to obtain all relevant and current documentation, to obtain the tools and equipment required for the assembly operations, checking that they are in a safe and usable condition. In carrying out the assembly operations, you will be required to follow company procedures and specified assembly techniques, in order to fit electrical and electronic components to the mechanical assembly.

The assembly activities will also include making all necessary checks and adjustments, to ensure that the electrical and electronic components, when fitted to the assembly, are checked for position, security, function, safety and completeness. You must also check that any cables and wires are routed correctly and are tidy in appearance, and that connections are mechanically sound and checked for electrical continuity.

Your responsibilities will require you to comply with organisational policy and procedures for the assembly activities undertaken, and to report any problems with the assembly activities, materials or equipment that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to ensure that all tools, equipment and materials used in the assembly are correctly accounted for on completion of the activities, and to complete all necessary job/task documentation accurately and legibly. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to electrical and electronic fitting and assembly techniques and procedures. You will understand the mechanical product being assembled, and its application, and will know about the equipment, relevant components and joining techniques, in adequate depth to provide a sound basis for carrying out the activities to the required specification.



321

Unit No 65: Fitting Electrical and Electronic Components to Mechanical AssembliesPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the relevant instructions, assembly drawings and any other specificationsc. Ensure that the specified components are available and that they are in a usable conditiond. Use the appropriate methods and techniques to assemble the components in their correct positionse. Secure the components using the specified connectors and securing devicesf. Check the completed assembly to ensure that all operations have been completed and the finished assembly meets the required specificationd. Deal promptly and effectively with problems within your control and report those that cannot be solved



● use the correct issue of drawings, job instructions and procedures● check calibration dates of tools and measuring instruments to be used● ensure the components used are free from damage, dirt or other contamination● apply safe and appropriate fitting and assembly techniques at all times● use lifting and slinging equipment in accordance with health and safety guidelines and procedures● leave the work area in a safe condition

2. Fit electrical, electronic and electromechanical components, using all of following techniques: ● routeing cables and wires ● mounting/securing components ● cable fixings and fasteners

3. Terminate and join cables/wires to components using three of the following: ● screwed connections ● clamped connections ● soldering ● crimping● cable protection devices (sleeving or grommets)

4. Make connections to six of the following components on mechanical assemblies: ● cables and wires● circuit protection devices● plugs● sockets● programme logic control units

● transformers● switches● sensors ● motors● pumps

● lamps/lighting ● junction boxes● earthing devices● coils ● chokes

● electronic modules● instrumentation● relays● other

5. Carry out the required checks using the correct tools and equipment, to include eight of the following: ● dimensions● position● alignment

● completeness● free from damage or foreign objects ● electronic inputs and outputs

● electrical inputs and outputs● function● component security

6. Produce mechanical assemblies which comply with one or more of the following standards: ● BS or ISO standards and procedures● customer standards and requirements ● company standards and procedures● specific system requirements


322

Unit No 65: Fitting Electrical and Electronic Components to Mechanical AssembliesKnowledge statements:


1. The specific safety precautions to be taken while carrying out the assembly, including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials


3. COSHH Regulations with regard to the substances used in the assembly process4. The hazards associated with producing assemblies, and how they can be minimised5. The personal protective equipment and clothing that needs to be worn during the assembly activities 6. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing8. How to extract the necessary information in order to fit electrical and electronic components to mechanical

assemblies9. The general principles of electrical and electronic fitting techniques; the purpose and function of the components

(including identification systems eg, colour codes, manufactures specification)10. Preparations that need to be undertaken on the electrical and electronic components prior to fitting them into the

assembly11. The correct component handling procedures, including relevant handling equipment, are identified and used12. The assembly and securing methods and procedures to be used, and the importance of adhering to these

procedures13. How the components are to be routed, aligned, adjusted and positioned prior to securing, and the tools and

equipment that are used 14. The importance of using the specified electrical and electronic components and securing devices for the assembly,

and why you must not use substitutes 15. The quality control procedures that need to be followed during the assembly operations 16. How to conduct any necessary checks to ensure the accuracy, position, security, function, completeness and

electrical continuity of the assembly17. How to detect assembly defects, and what to do to rectify them (ineffective joining techniques, component

damage)18. How to check that the tools and equipment to be used are correctly calibrated and are in a safe and serviceable

condition19. The importance of ensuring that all tools are used correctly and within their permitted operating range20. The importance of ensuring all tools, equipment and components are accounted for and returned to their correct

location on completion of the assembly activities21. Problems with the assembly operations, and the importance of informing appropriate people of non-conformances22. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


323

Unit No 66: Producing Power Turbine Combustion Assemblies

Unit Summary

This unit identifies the competencies you need to carry out assembly operations to produce turbine combustion assemblies, in accordance with approved procedures. You will be required to obtain all the required tools and equipment for the assembly operations, and to check that they are in a safe and usable condition. In carrying out the assembly operations, you will be required to follow laid-down procedures and specific assembly techniques, in order to assemble the various components and unit sub-assemblies into the combustor assembly.

The assembly activities will also include making all necessary checks and adjustments, to ensure that components are correctly orientated, positioned and aligned, that moving parts have the correct working clearances, that all fasteners are tightened to the correct torque, and that the assembled parts function as per the specification.

Your responsibilities will require you to comply with organisational policy and procedures for the assembly activities undertaken, and to report any problems with the assembly activities, materials or equipment that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to ensure that all tools, equipment and materials used in the installation are correctly accounted for on completion of the activities, and to complete all necessary job/task documentation accurately and legibly. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying the assembly techniques and procedures. You will understand the turbine combustor being assembled, and its application, and will know about the equipment, relevant components and fastening devices, in adequate depth to provide a sound basis for carrying out the activities to the required specification.



324

Unit No 66: Producing Power Turbine Combustion AssembliesPerformance statements:




● use the correct issue of engine/module drawings/overhaul manual and planning documentation● use copies of relevant COSHH sheets and risk assessment sheets● check calibration dates of tools and measuring instruments to be used● check components are free from damage or contamination prior to assembly● apply safe and appropriate assembly techniques● use lifting and slinging equipment in accordance with health and safety guidelines and procedures● leave the work area in a safe condition

2. Use six of the following assembly methods and techniques: ● assembly of components by pressure● assembly of components by expansion or contraction● aligning components● setting working clearances● torque setting of bolts, fasteners, clips, sub-assemblies

● applying sealants/adhesives● drilling, reaming and riveting● electrical bonding of components● blue-bedding components

● securing components using mechanical fasteners and threaded devices● applying bolt locking methods (split pins, wire locking, lock nuts, stiff nuts, swage nuts)

3. Produce the engine combustor/module assemblies by fitting all of the following: combustion casecombustion cans/chambersannular combustion chambersnozzle guide vanes

outer guide vanesseals and gasketsshims and packings

locking deviceswire thread inserts

● pipes and unions

4. Carry out all the following checks for accuracy, using the correct inspection testing equipment: ● positional accuracy ● freedom of movement ● component security ● completeness● dimensions ● orientation ● alignment ● function ● bearing end float● operating/working clearances ● free from damage or foreign objects

5. Produce turbine assemblies which comply with one of the following quality and accuracy standards: ● BS or ISO standards and procedures● customer standards and requirements

● company standards and procedures● specific system requirements


325

Unit No 66: Producing Power Turbine Combustion AssembliesKnowledge statements:


1. The specific safety precautions to be taken while carrying out the engine combustor/module assembly, including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials


3. COSHH Regulations with regard to the substances used in the assembly process 4. The hazards associated with producing engine combustor/module assemblies, and how they can be minimised5. The personal protective equipment and clothing that needs to be worn during the assembly activities6. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing8. How to identify the components to be used (component identification systems eg, codes and component

orientation indicators)9. Preparations that need to be undertaken on the components prior to fitting them into the assembly10. The assembly methods and procedures to be used, and the importance of adhering to these procedures11. How the components are to be aligned and positioned prior to securing, and the tools and equipment that are used

including jigs and fixtures12. The various mechanical fasteners that will be used and their method of installation (including bolts and nuts, rivets,

threaded fasteners, special securing devices)13. The importance of using the specified mechanical fastening devices for the assembly, and why you must not use

substitutes14. How to complete basic fitting practices, meeting company requirements (torque tightening, wire locking, fitting

wire thread inserts, fitting O-ring seals, fitting lock nuts, blue-bedding and swage nuts)15. How to ensure outer guide vanes and nozzle guide vanes are properly seated and assembled to achieve fit, position

and alignment16. Dealing with components or fastening devices incorrectly assembled, damaged or having other faults 17. The application of sealants and adhesives within the assembly activities, and the precautions that must be taken

when working with them 18. The quality control procedures that need to be followed during the assembly operations19. How to conduct any necessary checks to ensure the accuracy and quality of the assemblies produced 20. How to detect assembly defects, and what to do to rectify them (ineffective fasteners, foreign object damage)21. How to move large components and assemblies, the methods and equipment used to transport, handle and lift the

components into position22. How to check that the tools and equipment to be used are correctly calibrated and are in a safe and serviceable

condition23. The importance of ensuring that all tools are used correctly and within their permitted operating range24. The importance of ensuring that the completed assembly is free from dirt, swarf and foreign objects 25. The importance of ensuring all tools, equipment and components are accounted for and returned to their correct



326





required)evidence typedate carry out during assembly activities (all)use correct issue of engine/ module drawings/overhaul manual/planning documentationuse copies of relevant COSHH sheets/risk assessment sheetscheck calibration dates of tools/measuring instrumentscheck components are free from damage/contamination prior to assemblyapply safe/appropriate assembly techniquesuse lifting/slinging equipment in accordance with safety guidelines/proceduresleave work area in safe conditionuse assembly methods and techniques (six)assembly of components by pressureassembly of components by expansion/contractionaligning componentssetting working clearancestorque setting of bolts /clips/fasteners/sub-assemblessecure components using mechanical fasteners/ threaded devicesapplying bolt locking methodsapplying sealants/adhesivesdrilling, reaming and rivetingelectrical bonding of componentsblue-bedding componentsproduce the engine combustor/ module assemblies by fitting (all)combustion casecombustion cans/chambersannular combustion chambersnozzle guide vanesouter guide vanesseals and gasketsshims and packingslocking deviceswire thread insertspipes and unions






327

required)evidence typedate using the correct inspection equipment carry out checks for accuracy (all)positional accuracydimensionsoperating/working clearancesfreedom of movementorientationalignmentfree from damage or foreign objectscomponent securityfunctioncompletenessbearing end floatproduce turbine assemblies which comply with quality and accuracy standards (one)BS/ISO standards and procedurescustomer standards and requirementscompany standards and proceduresspecific system requirements


Candidate: Date:

Assessor: Date:


328

Unit No 67: Producing Power Turbine Compressor Assemblies

Unit Summary

This unit identifies the competencies you need to carry out assembly operations to produce turbine compressor assemblies, in accordance with approved procedures. You will be required to obtain all the appropriate tools and equipment for the assembly operations, and to check that they are in a safe and usable condition. In carrying out the assembly operations, you will be required to follow laid-down procedures and specific assembly techniques, in order to assemble the various components and unit sub-assemblies into the compressor assembly.



Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying the assembly techniques and procedures. You will understand the turbine compressor being assembled, and its application, and will know about the equipment, relevant components and fastening devices, in adequate depth to provide a sound basis for carrying out the activities to the required specification.



329

Unit No 67: Producing Power Turbine Compressor AssembliesPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the relevant instructions, assembly drawings and any other specificationsc. Ensure that the specified components are available and that they are in a usable conditiond. Use the appropriate methods and techniques to assemble the components in their correct positionse. Secure the components using the specified connectors and securing devicesf. Check the completed assembly to ensure that all operations have been completed and the finished assembly

meets the required specificationg. Deal promptly and effectively with problems within your control and report those that cannot be solved



● use the correct issue of engine/module drawings/overhaul manual and planning documentation● use copies of relevant COSHH sheets and risk assessment sheets● check calibration dates of tools and measuring instruments to be used● use lifting and slinging equipment in accordance with health and safety guidelines and procedures● check components are free from damage and contamination prior to assembly● apply safe and appropriate assembly techniques at all times● leave the work area in a safe condition

2. Use six of the following assembly methods and techniques: ● assembly of components by pressure● assembly of components by expansion or contraction● aligning components● setting working clearances● torque setting of bolts, clips, fasteners, sub-assemblies

● balancing of components ● applying sealant/adhesives● drilling, reaming and riveting● electrical bonding of components● blue-bedding components


3. Produce the compressor/module assembly by fitting six of the following: compressor housingcompressor statorscompressor bladescurvic couplings

sub-assemblies ● seals and gaskets● shims and packings

● locking devices● wire thread inserts● pipes and unions

4. Carry out all the following checks for accuracy, using the correct inspection testing equipment:● positional accuracy ● freedom of movement ● component security ● completeness● dimensions ● orientation ● alignment ● function ● bearing end float● operating/ working clearances ● free from damage or foreign objects

5. Produce turbine assemblies which comply with one of the following quality and accuracy standards:● BS or ISO standards and procedures● customer standards and requirements



330

Unit No 67: Producing Power Turbine Compressor AssembliesKnowledge statements:


1. The specific safety precautions to be taken while carrying out the engine compressor/module assembly, including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials


3. COSHH Regulations with regard to the substances used in the assembly process4. The hazards associated with producing turbine compressor assemblies, and how they can be minimised5. The personal protective equipment and clothing that needs to be worn during the assembly activities6. How to use and extract information from engineering drawings and related specifications, to include symbols and



orientation indicators)9. Preparations that need to be undertaken on the components prior to fitting them into the assembly10. The assembly methods and procedures to be used, and the importance of adhering to these procedures11. How the components are to be aligned and positioned prior to securing, and the tools and equipment that are

used, including jigs and fixtures12. The various mechanical fasteners that will be used and their method of installation (including bolts, nuts, rivets,


substitutes14. How to complete basic fitting practices to meet company requirements (torque tightening, wire locking, fitting wire

thread inserts, fitting O-ring seals, fitting lock nuts, blue-bedding and swage nuts)15. Dealing with components or fastening devices incorrectly assembled, damaged, or having other faults16. The application of sealants and adhesives within the assembly activities, and the precautions that must be taken

when working with them17. How to ensure curvic couplings are properly seated and assembled to achieve fit and alignment18. The quality control procedures that need to be followed during the assembly operations19. How to conduct any necessary checks to ensure the accuracy and quality of the assemblies produced 20. How to detect assembly defects, and what to do to rectify them (ineffective fasteners, foreign object damage)21. How to move large components and assemblies; the methods and equipment used to transport, handle and lift the

components into position22. How to check that the tools and equipment to be used are correctly calibrated and are in a safe and serviceable

condition23. The importance of ensuring that all tools are used correctly and within their permitted operating range24. The importance of ensuring that the completed assembly is free from dirt, swarf and foreign objects 25. The importance of ensuring all tools, equipment and components are accounted for and returned to their correct

location on completion of the assembly activities26. Problems with the assembly operations, and the importance of informing appropriate people of non-conformances27. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve.


331





required)evidence typedate carry out assembly activities (all)use correct issue of engine/ module drawings/overhaul manual/ planning documentationuse copies of relevant COSHH sheets/risk assessment sheetscheck calibration dates of tools/measuring instrumentsuse lifting/slinging equipment in accordance with health/ safety guidelines/procedurescheck components are free from damage/contamination prior to assemblyapply safe/appropriate assembly techniques leave work area safe conditionuse assembly methods and techniques (six)assembly of components by pressureassembly of components by expansion/contractionaligning componentssetting working clearancestorque setting of bolts/clips/ fasteners/threaded devicessecuring components using mechanical fasteners/ threaded devicesapplying bolt locking methodsapplying sealants/adhesivesdrilling, reaming and rivetingelectrical bonding ofcomponentsblue-bedding componentsbalancing of componentsproduce compressor/module assembly (six)compressor housingcompressor statorscompressor bladescurvic couplingssub-assembliesseals and gasketsshims and packingslocking deviceswire thread insertspipes and unions


332





required)evidence typedate carry out checks for accuracy, using the correct inspection testing equipment (all)positional accuracydimensionsoperating/working clearancesfreedom of movementorientationalignmentfree from damage or foreign objectscomponent securityfunctioncompletenessbearing end floatproduce turbine assemblies which comply with quality and accuracy standards (one)BS/ISO standards and procedurescustomer standards and requirementscompany standards and proceduresspecific system requirements


Candidate: Date:

Assessor: Date:


333

Unit No 68: Producing Turbine Assemblies

Unit Summary

This unit identifies the competencies you need to carry out assembly operations to produce turbine assemblies, in accordance with approved procedures. You will be required to obtain all the appropriate tools and equipment for the assembly operations, and to check that they are in a safe and usable condition. In carrying out the assembly operations, you will be required to follow laid-down procedures and specific assembly techniques, in order to assemble the various unit sub-assemblies and components into the turbine assembly.

The assembly activities will also include making all necessary checks and adjustments to ensure that components are correctly orientated, positioned and aligned, that moving parts have the correct working clearances, that all fasteners are tightened to the correct torque, and that the assembled parts function as per the specification.


Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying the assembly techniques and procedures. You will understand the turbine assembly being assembled, and its application, and will know about the equipment, relevant components and fastening devices, in adequate depth to provide a sound basis for carrying out the activities to the required specification.



334

Unit No 68: Producing Turbine Assemblies Performance statements:




● use the correct issue of module assembly drawings/overhaul manual and planning documentation● use copies of relevant COSHH sheets and risk assessment sheets● check calibration dates of tools and measuring instruments to be used● use lifting and slinging equipment in accordance with health and safety guidelines and procedures● check components are free from damage or contamination prior to assembly● apply safe and appropriate assembly techniques at all times● leave the work area in a safe condition




3. Produce the turbine assemblies by fitting six of the following: low pressure turbineintermediate pressure turbinehigh pressure turbineturbine shaftsturbine discs

turbine blades bearing racesbearingsseals and gasketsshims and packings

wire thread insertslocking devices

● pipes and unions

4. Carry out all the following checks for accuracy, using the correct inspection testing equipment: ● dimensions● positional accuracy● freedom of movement

● bearing end float● orientation● alignment

● operating/working clearance● completeness ● freedom from damage or foreign objects

5. Produce turbine assemblies which comply with one or more of the following standards: ● BS or ISO standards and procedures● customer standards and requirements



335

Unit No 68: Producing Turbine Assemblies Knowledge statements:


1. The specific safety precautions to be taken while carrying out the turbine assembly, including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials


3. COSHH Regulations with regard to the substances used in the assembly process4. The hazards associated with producing turbine assemblies, and how they can be minimised5. The personal protective equipment and clothing that needs to be worn during the assembly activities6. How to use and extract information from engineering drawings and related specifications, to include symbols and



orientation indicators)9. Preparations that need to be undertaken on the components prior to fitting them into the assembly10. The assembly methods and procedures to be used, and the importance of adhering to these procedures11. How the components are to be aligned and positioned prior to securing, and the tools and equipment that are used

including jigs and fixtures12. The various mechanical fasteners that will be used, and their method of installation (including bolts, nuts, rivets,


substitutes14. How to complete basic fitting practices meeting company requirements (torque tightening, wire locking, fitting wire

thread inserts, fitting O-ring seals, fitting lock nuts, blue-bedding and swage nuts)15. Dealing with components or fastening devices incorrectly assembled, damaged, or having other faults16. How to assemble and fit turbine shafts and discs into the module assembly17. How to ensure curvic couplings are properly seated and assembled to achieve fit and alignment18. The application of sealants and adhesives within the assembly activities, and the precautions that must be taken

when working with them19. The quality control procedures that need to be followed during the assembly operations 20. How to conduct any necessary checks to ensure the accuracy and quality of the assemblies produced21. How to detect assembly defects, and what to do to rectify them (ineffective fasteners, foreign object damage)22. How to move large components and assemblies; the methods and equipment used to transport, handle and lift the

components into position; and how to check that the equipment is within its current certification dates23. How to check that the tools and equipment to be used are correctly calibrated and are in a safe and serviceable

condition24. The importance of ensuring that all tools are used correctly and within their permitted operating range25. The importance of ensuring that the completed assembly is free from dirt, swarf and foreign objects26. The importance of ensuring all tools, equipment and components are accounted for and returned to their correct



336





required)evidence typedate carry out during assembly activities (all)use correct issue of module assembly drawings/overhaul manual/planning documentationuse copies of relevant COSHH sheets/risk assessment sheetscheck calibration dates of tools/measuring instrumentsuse lifting/slinging equipment in accordance with health & safety guidelines/procedurescheck components are free from damage/contamination prior to assemblyapply safe/appropriate assembly techniques at all timesleave work area in safe conditionassembly methods and techniques (six)assembly of components by pressureassembly of components by expansion/contractionaligning componentssetting working clearancestorque setting of bolts/clips/ fasteners/sub-assembliessecuring components using mechanical fasteners/ threaded devicesapplying bolt locking methodsapplying sealants/adhesivesdrilling, reaming and rivetingelectrical bonding of componentsblue-bedding componentsbalancing of componentsproduce turbine assemblies which comply to standards (six)low pressure turbine intermediate pressure turbinehigh pressure turbineturbine shaftsturbine discsturbine blades bearing racesbearingsseals and gasketsshims and packingswire thread insertslocking devicespipes and unions






337

required)evidence typedate carry out check s for accuracy using the correct inspection testing equipment (all)dimensionspositional accuracyfreedom of movementbearing end floatorientationalignmentoperating/working clearancecompletenessfreedom from damage or foreign objectsproduce turbine assemblies which comply with standards (one)BS/ISO standards and procedurescustomer standards and requirementscompany standards and proceduresspecific system requirements


Candidate: Date:

Assessor: Date:


338

Unit No 69: Producing Power Turbine Gearbox Assemblies

Unit Summary

This unit identifies the competencies you need to carry out assembly operations to produce turbine gearbox assemblies, in accordance with approved procedures. You will be required to obtain all the appropriate tools and equipment for the assembly operations, and to check that they are in a safe and usable condition. In carrying out the assembly operations, you will be required to follow laid-down procedures and specific assembly techniques, in order to assemble the various components and unit sub-assemblies into the gearbox assembly.



Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying the assembly techniques and procedures. You will understand the turbine gearbox being assembled, and its application, and will know about the equipment, relevant components and fastening devices, in adequate depth to provide a sound basis for carrying out the activities to the required specification.



339

Unit No 69: Producing Power Turbine Gearbox AssembliesPerformance statements:




● use the correct issue of engine/module drawings/overhaul manual and planning documentation● use copies of relevant COSHH sheets and risk assessment sheets● check calibration dates of tools and measuring instruments to be used● use lifting and slinging equipment in accordance with health and safety guidelines and procedures● check components are free from damage or contamination prior to assembly● apply safe and appropriate assembly techniques at all times● leave the work area in a safe condition




3. Produce the turbine gearbox assemblies by fitting six of the following: gear housingslay shaftstemperature sensors

bearingstorque converterslocking devices

seals and gasketsstarter unitswire thread inserts

drive shaftslevers and linkagesshims and packings

gear trains/sub-assemblies● pipes and unions

4. Carry out all the following checks for accuracy, using the correct inspection testing equipment: ● positional accuracy ● freedom of movement ● component security ● completeness● dimensions ● orientation ● alignment ● function ● bearing end float● operating/ working clearances ● free from damage or foreign objects

5. Produce turbine gearbox assemblies which comply with one of the following quality and accuracy standards:● BS or ISO standards and procedures● customer standards and requirements



340

Unit No 69: Producing Power Turbine Gearbox AssembliesKnowledge statements:


1. The specific safety precautions to be taken while carrying out the engine gearbox assembly, including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials


3. COSHH Regulations with regard to the substances used in the assembly process 4. The hazards associated with producing aircraft engine gearbox assemblies, and how they can be minimised5. The personal protective equipment and clothing that needs to be worn during the assembly activities6. How to use and extract information from engineering drawings and related specifications, to include symbols and



orientation indicators)9. Preparations that need to be undertaken on the components prior to fitting them into the assembly10. The assembly methods and procedures to be used, and the importance of adhering to these procedures11. How the components are to be aligned and positioned prior to securing, and the tools and equipment that are

used, including jigs and fixtures12. The various mechanical fasteners that will be used, and their method of installation (including bolts, nuts, rivets,


substitutes14. How to complete basic fitting practices meeting regulatory and organisational requirements (torque tightening,

wire locking, fitting wire thread inserts, fitting O-ring seals, fitting lock nuts, blue-bedding and swage nuts)15. Dealing with components or fastening devices incorrectly assembled, damaged, or having other faults16. The application of sealants and adhesives within the assembly activities and the precautions that must be taken

when working with them17. The quality control procedures that need to be followed during the assembly operations18. How to conduct any necessary checks to ensure the accuracy and quality of the assemblies produced 19. How to detect assembly defects, and what to do to rectify them (ineffective fasteners, foreign object damage)20. How to move large components and assemblies; the methods and equipment used to transport, handle and lift the

components into position; and how to check that the equipment is within its current certification dates21. How to check that the tools and equipment to be used are correctly calibrated and are in a safe and serviceable




341





required)evidence typedate carry out during assembly activities (all)use correct issue of engine/ module drawings/overhaul manual/planning documentationuse copies of relevant COSHH sheets/risk assessment sheetscheck calibration dates of tools/measuring instrumentsuse lifting/slinging equipment in accordance with health & safety guidelines/procedurescheck components are free from damage/contamination prior to assemblyapply safe/appropriate assembly techniques leave work area in safe conditionassembly methods and techniques (six)assembly of components by pressureassembly of components by expansionaligning componentssetting working clearancestorque setting of bolts/clips/ fasteners/sub-assembliessecuring components using mechanical fasteners/ threaded devicesapplying bolt locking methodsapplying sealants/adhesivesdrilling, reaming and rivetingelectrical bonding of componentsblue-bedding componentsbalancing of componentsproduce turbine gearbox assemblies by fitting (six)gear housinglay shaftstemperature sensorsgear trains/sub-assembliespipes and unionsbearings torque converterslocking devicesseals and gasketsstarter unitswire thread insertsdrive shaftslevers and linkagesshims and packings






342


evidence typedate carry out checks for accuracy, using the correct inspection testing equipment (all)dimensionspositional accuracyfreedom of movementbearing end floatorientationalignmentoperating/working clearancecomponent securityfunctioncompletenessfree from damage or foreign objectsproduce turbine gearbox assemblies which comply with standards (one)BS/ISO standards and procedurescustomer standards and requirementscompany standards and proceduresspecific system requirements


Candidate: Date:

Assessor: Date:


343

Unit No 70: Producing Power Turbine Major Assemblies

Unit Summary

This unit identifies the competencies you need to carry out assembly operations to produce major assemblies of power turbines, in accordance with approved procedures. This unit covers the assembly of modules into part and final assemblies. You will be required to obtain all the appropriate tools and equipment for the assembly operations, and to check that they are in a safe and usable condition. In carrying out the assembly operations, you will be required to follow laid-down procedures and specific assembly techniques, in order to assemble the various sub-assembly units and components into the major assembly.



Your underpinning knowledge will provide a good understanding of your work, and will provide an informedapproach to applying the assembly techniques and procedures. You will understand the turbine being assembled, and its application, and will know about the equipment, relevant components and fastening devices, in adequate depth to provide a sound basis for carrying out the activities to the required specification.



344

Unit No 70: Producing Power Turbine Major Assemblies Performance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the relevant instructions, assembly drawings and any other specificationsc. Ensure that the specified components are available and that they are in a usable conditiond. Use the appropriate methods and techniques to assemble the components in their correct positionse. Secure the components using the specified connectors and securing devicesf. Check the completed assembly to ensure that all operations have been completed and the finished assembly

meets the required specificationg. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must:1. Carry out all the following during the assembly activities

● use the correct issue of assembly drawings/overhaul manual and planning documentation● check calibration dates of tools and measuring instruments to be used● ensure all modules/units to be assembled are undamaged and free from foreign objects● use lifting and slinging equipment in accordance with health and safety guidelines and procedures● apply safe and appropriate fitting and assembly techniques at all times● leave the work area in a safe condition

2. Use five of the following assembly methods and techniques:● assembly of components by pressure● assembly of components by expansion or contraction● aligning components● setting working clearances● torque setting of bolts, fasteners, clips, sub-assemblies

● applying sealants/adhesives● drilling and riveting● electrical bonding of components● aligning auxiliary equipment

● securing components using mechanical fasteners and threaded devices:● applying bolt locking methods (split pins, wire locking, lock nuts, stiff nuts)

3. Produce the assembly by fitting two of the following: ● front fan and fan case● compressor module● combustor module● turbine

● gear box● outer casings● air intake ducts● exhaust systems

4. Carry out all the following checks for accuracy, using the correct inspection testing equipment: ● positional accuracy ● freedom of movement ● component security ● completeness● dimensions ● orientation ● alignment ● function ● bearing end float● operating/ working clearances ● free from damage or foreign objects

5. Produce assemblies which comply with one of the following quality and accuracy standards:● BS or ISO standards and procedures● customer standards and requirements ● company standards and procedures● specific system requirements


345

Unit No 70: Producing Power Turbine Major Assemblies Knowledge statements:


1. The specific safety precautions to be taken while carrying out the assembly, including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials


3. COSHH Regulations with regard to the substances used in the assembly process4. The hazards associated with producing assemblies, and how they can be minimised5. The personal protective equipment and clothing that needs to be worn during the assembly activities6. How to use and extract information from engineering drawings and related specifications, to include symbols


reference points and system of tolerancing8. How to identify the components to be used (component identification systems eg, codes and component

orientation indicators)9. Preparations that need to be undertaken on the components prior to fitting them into the assembly10. The assembly methods and procedures to be used, and the importance of adhering to these procedures 11. How the components are to be aligned and positioned prior to securing, and the tools and equipment that are



substitutes14. How to complete basic fitting practices meeting regulatory and organisational requirements (torque tightening,

wire locking, fitting wire thread inserts, fitting O-ring seals, fitting lock nuts, blue-bedding, ‘corrujoint’ seals, tab washers, cup washers and swage nuts)

15. Dealing with components or fastening devices incorrectly assembled, damaged, or having other faults16. The application of sealants and adhesives within the assembly activities, and the precautions that must be taken

when working with them17. The quality control procedures that need to be followed during the assembly operations18. How to conduct any necessary checks to ensure the accuracy and quality of the assemblies produced19. How to detect assembly defects, and what to do to rectify them (ineffective fasteners, foreign object damage)20. How to move large components sub-assemblies and assemblies; the methods and equipment used to transport,

handle and lift the components into position21. How to check that the tools and equipment to be used are correctly calibrated and are in a safe and serviceable


location on completion of the assembly activities25. Problems with the assembly operations, and the importance of informing appropriate people of non-

conformances26. The extent of your own responsibility and whom you should report to if you have problems that you cannot

resolve


346





required)evidence typedate carry out during assembly activities (all)use correct issue of assembly drawings/overhaul manual/planning documentationcheck calibration dates of tools/measuring instrumentsensure modules/units are undamaged and free from foreign objectsuse lifting/slinging equipment in accordance with health & safety guidelines/proceduresapply safe/appropriate fitting/ assembly techniques leave work area in safe conditionassembly methods and techniques (six)assembly of components by pressureassembly of components by expansion/contractionaligning componentssetting working clearancestorque setting of bolts/clips/ fasteners/threaded devicesusing mechanical fastenersapplying bolt locking methodsapplying sealants/adhesivesdrilling and rivetingelectrical bonding of componentsaligning auxiliary equipmentproduce the assembly by fitting (two)front fan and fan casecompressor modulecombustor moduleturbinegear boxouter casingsair intake ductsexhaust systemscarry out checks for accuracy, using the correct inspection testing equipment (all)dimensionspositional accuracyfreedom of movementbearing end floatorientationalignmentoperating/working clearancecomponent securityfunctioncompletenessdamage or foreign objects






347


evidence typedate produce assemblies which comply with standards (one)BS/ISO standards and procedurescustomer standards and requirementscompany standards and proceduresspecific system requirements


Candidate: Date:

Assessor: Date:


348

Unit No 71: Producing Piston Engine Assemblies

Unit Summary

This unit identifies the competencies you need to carry out assembly operations to produce piston engine assemblies, in accordance with approved procedures. You will be required to obtain all the appropriate tools and equipment for the assembly operations, and to check that they are in a safe and usable condition. In carrying out the assembly operations, you will be required to follow laid-down procedures and specific assembly techniques, in order to assemble the various components and unit sub-assemblies into the piston engine assembly.



Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying the assembly techniques and procedures. You will understand the piston engine being assembled, and its application, and will know about the equipment, relevant components and fastening devices, in adequate depth to provide a sound basis for carrying out the activities to the required specification.



349

Unit No 71: Producing Piston Engine Assemblies Performance statements:




● use the correct issue of engine/sub-assembly drawings and planning documentation● use copies of relevant COSHH sheets and risk assessment sheets● check calibration dates of tools and measuring instruments to be used● use lifting and slinging equipment in accordance with health and safety guidelines and procedures● check that components are free from damage or contamination before assembling them● apply safe and appropriate assembly techniques at all times ● leave the work area in a safe condition

2. Use five of the following assembly methods and techniques: ● assembly of components by pressure● assembly of components by expansion or contraction● aligning components● setting working clearances● torque setting of bolts, fasteners, clips, sub-assemblies

● balancing of components ● applying sealants/adhesives● drilling, reaming and riveting● electrical bonding of components● blue-bedding components


3. Produce the piston engine assembly by fitting twelve of the following: cylinder blockcylinder headscrank shaftsfly wheeltorque converterspiston assemblies

crank shafts camshaft assembliestiming mechanismsvalve mechanismsoil pumps bearings

seals and gasketspulleys and sprocketsbelts and chains levers and linkages injector mechanismssensing devices

manifoldssump pansexhaust systemspipes and unionsfuel pumpsother components

4. Carry out all the following checks for accuracy, using the correct inspection testing equipment: ● dimensions● positional accuracy/timing● freedom of movement ● operating/working clearance ● bearing end float

● orientation● alignment● completeness ● freedom from damage or foreign objects

5. Produce turbine gearbox assemblies which comply with one of the following quality and accuracy standards:● BS or ISO standards and procedures● customer standards and requirements



350

Unit No 71: Producing Piston Engine Assemblies Knowledge statements:


1. The specific safety precautions to be taken while carrying out the piston engine/sub-unit assembly, including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials


3. COSHH Regulations with regard to the substances used in the assembly process4. The hazards associated with producing aircraft piston engine assemblies, and how they can be minimised5. The personal protective equipment and clothing that needs to be worn during the assembly activities6. How to use and extract information from engineering drawings and related specifications, to include symbols and



orientation indicators)9. Preparations that need to be undertaken on the components prior to fitting them into the assembly 10. The assembly methods and procedures to be used, and the importance of adhering to these procedures11. How to complete basic fitting practices meeting company requirements (torque tightening, wire locking, fitting wire

thread inserts, fitting O-ring seals, fitting lock nuts, blue-bedding and swage nuts)12. How the components are to be aligned and positioned prior to securing, and the tools and equipment that are



substitutes15. COSHH Regulations with regard to the substances used in the assembly process16. Dealing with components or fastening devices incorrectly assembled, damaged, or having other faults17. The application of sealants and adhesives within the assembly activities, and the precautions that must be taken

when working with them18. The quality control procedures that need to be followed during the assembly operations19. How to conduct any necessary checks to ensure the accuracy and quality of the assemblies produced20. How to detect assembly defects, and what to do to rectify them (ineffective fasteners, foreign object damage)21. How to move large components and assemblies; the methods and equipment used to transport, handle and lift the

components into position; and how to check that the equipment is within its current certification dates.22. How to check that the tools and equipment to be used are correctly calibrated and are in a safe and serviceable




351





required)evidence typedate carry out during assembly activities (all)use correct issue of engine/ sub-assembly drawings/ planning documentationuse copies of relevant COSHH sheets/risk assessment sheetscheck calibration dates of tools/measuring instrumentsuse lifting/slinging equipment in accordance with health & safety guidelines/procedurescheck components are free from damage/contamination before assembling themapply safe/appropriate assembly techniquesleave work area in safe conditionuse assembly methods and techniques (five)assembly of components by pressureassembly of components by expansion/contractionaligning componentssetting working clearancestorque setting of bolts/clips/ fasteners/sub-assembliessecuring components using mechanical fasteners/ threaded devicesapplying bolt locking methodsbalancing of componentsapplying sealants/adhesivesdrilling, reaming and rivetingelectrical bonding of componentsblue-bedding components


352





required)evidence typedate produce the piston engine assembly fitting (twelve)cylinder blockcylinder headscrank shaftsfly wheeltorque converterspiston assembliescrank shaftscamshaft assembliestiming mechanismsvalve mechanismsoil pumpsbearingsseals and gasketspulleys and sprocketsbelts and chainslevers and linkagesinjector mechanismssensing devicesmanifoldssump pansexhaust systemspipes and unionsfuel pumpsother componentscarry out checks for accuracy, using the correct inspection testing equipment (all)dimensionspositional accuracy/timingfreedom of movementoperating/working clearancebearing end floatorientationalignmentcompletenessfreedom from damage or foreign objectsproduce mechanical assemblies standards (one)BS/ISO standards and procedurescustomer standards and requirementscompany standards and proceduresspecific system requirements


Candidate: Date:

Assessor: Date:


353

Unit No 72: Repairing and Modifying Mechanical Assemblies

Unit Summary

This unit identifies the competencies you need to carry out modifications on mechanical assemblies, in accordance with approved procedures. The assembly may have to be modified for a number of reasons, which could include performance out of specification, inherent design problems, changes to customer specification, or assembly problems. You will be required to prepare the work area, ensuring it is safe and free from hazards, to check the correct component parts requiring modification are available, to obtain all relevant and current documentation, and to obtain the tools and equipment required for the modification, checking that they are in a safe and usable condition. In carrying out the modification, you will be required to follow the appropriate company procedures and specified techniques.

The assembly and its components could be modified using a number of methods and techniques including, where appropriate, adjusting, removing and replacing, or repairing, or by manufacturing new components by machining, welding, fabricating or bonding. Component parts that are modified must be checked for accuracy, security, completeness, and that they function as per the specification.

Your responsibilities will require you to comply with organisational policy and procedures for the modification activities undertaken, and to report any problems with the modification activities, materials or equipment that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to ensure that all tools, equipment and materials used in the modification are correctly accounted for on completion of the activities, and to complete all necessary job/task documentation accurately and legibly. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying the modification methods, techniques and procedures. You will understand the mechanical product being modified, including its application and reason for the modification, and will know about the tools and equipment required, in adequate depth to provide a sound basis for carrying out the activities to the required specification.

You will understand the safety precautions required when carrying out the modification activities. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.


354

Unit No 72: Repairing and Modifying Mechanical AssembliesPerformance statements:

You must:

a Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb Obtain the relevant specification and job instructions for the modification being performedc Confirm and agree what modification is to be carried out to meet the specificationd Determine how the product and / or asset will be prepared for the modificatione Check that any materials and equipment required are available and that they are suitable for the work to be carried outf Carry out the modification to achieve the required changes, in line with agreed instructions and specificationsg Complete relevant documentation in accordance with organisational requirementsh Deal promptly and effectively with problems within your control and report those that cannot be solved


You must:1. Carry out all the following during the modification activities:

● use the correct issue of drawings, job instructions and specifications● use copies of relevant COSHH sheets and risk assessment sheets● check calibration dates of tools and measuring instruments to be used● ensure the components and pipes used are free from foreign objects, dirt or other contamination● use lifting and slinging equipment in accordance with health and safety guidelines and procedures● apply safe and appropriate modification and repair techniques● leave the work area in a safe condition

2. Carry out the modification using two of the following methods: ● adjustment● remove and replace with new components

● modify existing components● manufacture of new components

3. Complete the modification using two of the following techniques: ● dismantling and re-assembling● hand fitting ● electrical fitting and assembly● fluid power fitting and assembly● bonding

● adjusting● welding ● fabrication● machining

4. Carry out modifications on one of the following parts of the assembly: ● holding mechanism● operating system● control mechanism

● drive mechanism● fluid power system● delivery system

● transfer system● pipework system● safety mechanism

● assembly structure (framework, casings, panels) ● other5. Carry out the quality checks, to include eight from the following, using appropriate equipment:

● dimensions● positional accuracy● freedom of movement● operating/working clearances

● orientation● alignment● completeness● component security

● bearing end float● function● earth bonding and electrical continuity ● free from damage or foreign objects

6. Ensure the repairs and modifications comply with one of the following quality and accuracy standards:● BS or ISO standards and procedures● customer standards and requirements



355

Unit No 72: Repairing and Modifying Mechanical AssembliesKnowledge statements:


1. The specific safety precautions to be taken while carrying out modifications on mechanical assemblies, including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials

2. The health and safety requirements of the work area in which you are carrying out the modification activities, and the responsibility these requirements place on you

3. COSHH Regulations with regard to the substances used in the modification process4. The hazards associated with modifying mechanical assemblies, and how they can be minimised5. The personal protective equipment and clothing that needs to be worn during the modification activities6. The various types of drawing and specifications that are used during the modification7. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing9. The reasons why mechanical assemblies may require modification10. Preparations that need to be undertaken on the components prior to carrying out the modification11. The various methods that could be used to modify assemblies (adjust, remove and replace, repair and

manufacture)12. The basic concepts and techniques that can be used, where appropriate, to modify the assembly (machining,

welding fabrication, bonding, mechanical, electrical and electronic fitting)13. The quality control procedures that need to be followed during the modification, and the importance of adhering to

them14. How to conduct any necessary checks to ensure the accuracy, position, security, function and completeness of the

modification15. The methods and equipment used to transport, lift and handle components and assemblies16. How to check that the tools and equipment to be used are correctly calibrated and are in a safe and serviceable

condition17. The importance of ensuring that all tools are used correctly and within their permitted operating range18. The importance of ensuring all tools, equipment and components are accounted for and returned to their correct

location on completion of the modification activities19. Problems associated with carrying out modifications on mechanical assemblies, and the importance of informing

appropriate people of non-conformances20. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


356





required)evidence typedate carry out during modification activities (all)use correct issue of drawings/job instructions/ specificationsuse copies of relevant COSHH sheets/risk assessment sheetscheck calibration dates of tools/measuring instrumentsensure components/pipes are free from foreign objects/ dirt/other contaminationuse lifting/slinging equipment in accordance with health & safety guidelines/proceduresapply safe/appropriate modification/repair techniquesleave work area in safe conditioncarry out modification using methods (two)adjustmentremove/replace with new componentsmodify existing componentsmanufacture of new componentscomplete the modification using techniques (two)dismantling/ re-assemblinghand fittingelectrical fitting and assemblyfluid power fitting/assemblybondingadjusting weldingfabricationmachiningcarry out modifications (one)holding mechanismsoperating systemscontrol mechanismsassembly structuredrive mechanismsfluid power systemdelivery systemtransfer systempipework systemsafety mechanismsother



357


required)evidence typedate carry out quality checks using appropriate equipment (eight)dimensionspositional accuracyfreedom of movementoperating/working clearanceorientationalignmentcompletenesscomponent securitybearing end float functionearth bonding/electrical continuityfree from damage or foreign objectsensure repairs and modifications comply with standards (one)BS/ISO standards and procedurescustomer standards and requirementscompany standards and proceduresspecific system requirements


Candidate: Date:

Assessor: Date:


358

Unit No 73: Checking Completed Assemblies Comply with Specification

Unit Summary

This unit identifies the competencies you need to carry out checks on mechanical assemblies, in accordance with approved procedures. You will be required to prepare the work area, ensuring it is safe and free from hazards, to obtain all relevant and current documentation, and to obtain the tools and equipment required for the checking of mechanical assemblies, making sure that they are calibrated and in a safe and usable condition.

You will be expected to conduct ongoing trials, manual checks and operational checks throughout the assembly operations, and checks on component parts and sub-assemblies will also be carried out, where appropriate. You will be responsible for confirming the assembly is complete, fit for purpose, and meets the operational performance required by the specification. In carrying out checks on mechanical assemblies, you will also be required to complete any relevant documentation accurately and legibly.

Your responsibilities will require you to comply with organisational policy and procedures for checking the mechanical assembly, and to report any problems with the assembly you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to ensure that all tools and equipment used in checking the assembly are correctly accounted for on completion of the activities and returned to the correct location. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying quality control techniques and procedures including, where appropriate, British, European and International standards. You will understand the mechanical product being assembled, and its application, and will know about the tools and equipment used to check the assembly, in adequate depth to provide a sound basis for carrying out the activities to the required specification. You will understand the types of defect that can be found on the assembly, and how critical these defects are in determining the satisfactory performance of the completed product.



359

Unit No 73: Checking Completed Assemblies Comply with Specification Performance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow and make appropriate use of the specifications for the product or asset being checkedc. Use all the correct tools and inspection equipment and check that they are in useable conditiond. Carry out the checks in an appropriate sequence using approved methods and procedurese. Identify and assess any defects or variations from the specification and take appropriate actionf. Report completion of compliance activities in line with organisational procedures


You must:1. Carry out all the following during the checking activities:

● use the correct issue of drawings, job instructions and specifications● check calibration dates of tools and measuring instruments to be used● ensure all exposed openings are free from foreign objects, dirt or other contamination● use appropriate and safe inspection and checking techniques at all times● leave the work area in a safe condition

2. Check the mechanical assembly using twelve of the following instruments and gauges: ● rule or tape● levels● straight edges

● micrometers● feeler gauges● gauges

● vernier gauges● slip gauges● torque wrench

● protractors● squares● flow meters

● dial test indicator● temperature gauges● optical equipment

● electrical measuring equipment● pressure gauges● other specific equipment

3. Use the relevant equipment to measure and check seven of the following features: ● flatness● squareness● concentricity

● alignment● level ● verticality

● fit/working clearance● angles● dimensions

● parallelism● position/location● bonding strength

● distortion● torque

4. Check the operational functions of the mechanical assembly, to include ten of the following: ● rotation● direction● sliding● timing

● speed● pressure● flow● reciprocation

● movement ● balance ● vibration● temperature

● tension● electrical in/outputs● fluid power in/outputs● safety mechanisms

● sequence● distance/travel● noise● leakage

● power ● service supplies (water, gas, air, electrical supply)5. Ensure the completed assembly meets the specification using two of the following checks:

● trial ● under power ● fully operational ● manual check6. Check mechanical assemblies comply with one of the following quality and accuracy standards:

● BS or ISO standards and procedures● customer standards and requirements ● company standards and procedures● specific system requirements


360

Unit No 73: Checking Completed Assemblies Comply with Specification Knowledge statements:


1. The specific safety precautions to be taken while carrying out the mechanical assembly checks, including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials

2. The health and safety requirements of the work area in which you are carrying out the assembly checking activities, and the responsibility these requirements place on you

3. COSHH Regulations with regard to the substances used in the assembly process4. The hazards associated with checking mechanical assemblies, and how they can be minimised5. The personal protective equipment and clothing that needs to be worn during the assembly checking activities6. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing8. The use of British, European and international standards in determining if components and products are fit for

purpose9. The general principles of quality assurance systems and procedures10. The various stages when the assembly should be checked, and to what level11. Preparations that need to be undertaken before the assembly is checked12. The application of the various tools and equipment used to check the assembly13. The importance of ensuring tools and equipment are set up correctly and are in a safe and useable condition14. The procedure and methods used to check tools and equipment are within calibration date 15. The quality control procedures that need to be followed when checking the assembly16. How to conduct any necessary checks to ensure the safety, accuracy, position, security, function and completeness

of the assembly17. The types of defect that can be found on mechanical assemblies, and why they occur18. How to detect assembly defects, and what to do to rectify them19. The factors to be considered when determining if assembly components or products should be scrapped or

modified20. The documentation that needs to be completed to confirm the assembly has been properly checked21. The importance of ensuring all tools and equipment are returned to their correct location on completion of the

assembly checking activities22. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


361





required)evidence typedate carry out during the checking activities (all)use correct issue of drawings /job instructions/specificationscheck calibration dates of tools/measuring instrumentsensure all exposed openings are free from foreign objects/ dirt/other contaminationuse safe/appropriate inspection and checking techniquesleave the work area in a safe conditioncheck mechanical assembly using instruments and gauges (twelve)rule or tapelevelsstraight edgeselectrical measuring equipmentpressure gaugesother specific equipmentmicrometersfeeler gaugesgaugesvernier gaugesslip gaugestorque wrench protractorssquares flow metersdial test indicatortemperature gaugesoptical equipmentuse relevant equipment to measure and check features (seven)flatnesssquarenessconcentricityalignmentlevelverticalityfit/working clearanceanglesdimensionsparallelismposition/locationbonding strengthdistortiontorque


362





required)evidence typedate check operational functions of the mechanical assembly (ten)rotationdirectionsliding timingpowerspeed pressureflowreciprocationservice suppliesmovementbalancevibrationtemperaturetensionelectrical in/outputsfluid power in/outputssafety mechanismssequencedistance/travelnoiseleakageusing checks, ensure completed assembly meets the specification (two)trialunder powerfully operationalmanual checkcheck mechanical assemblies comply with standards (one)BS/ISO standards and procedurescustomer standards and requirementscompany standards and proceduresspecific system requirements


Candidate: Date:

Assessor: Date:


363

Unit No 74: Pipe Bending and Forming by Hand Methods

Unit Summary

This unit identifies the competencies you need to bend and form ferrous, non-ferrous and/or non-metallic pipe, using hand methods, in accordance with approved procedures. In producing pipe bends and forms, you will be expected to select and use a range of hand tools, forming equipment and techniques, which are appropriate to the type of material and operations being performed.

Activities will include cutting the pipes to the required lengths using hand sawing, band sawing or pipe/cutting machines, bending pipes using hand bending machines, springs, fillers or heating techniques, and the use of templates or set wires to check bend profiles. The pipework produced will have the features that include angular bends, offsets, bridge sets and expansion loops.

Your responsibilities will require you to comply with organisational policy and procedures for the pipe bending and forming activities undertaken, and to report any problems with the equipment, materials or pipe bending activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying pipe bending and forming procedures. You will understand the pipe bending and forming activities, and their application, and will know about the pipe bending and forming equipment and techniques, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the work output is completed to the required specification.

You will understand the safety precautions required when carrying out the pipe bending activities and using the associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.


364

Unit No 74: Pipe Bending and Forming by Hand MethodsPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the correct component drawing and any other related specifications for the component to be producedc. Determine what has to be done and how this will be achievedd. Use the appropriate tools and equipment for the pressure shaping operations and check that they are in a safe and usable conditione. Shape the materials to the required specification using appropriate methods and techniquesf. Check that all the required shaping operations have been completed to the required standardg. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must:1. Carry out all the following activities during hand forming and bending:

● use the correct issue of drawings, specifications and quality documentation● check that bending and forming equipment is in a safe and usable condition● apply safe working practices at all times● return all tools and equipment to the correct location on completion of the activities● leave the work area in a safe condition

2. Mark out pipework using two of the following methods: ● direct marking using tapes and markers● set-outs of pipework using templates

● producing set wires● set-outs of pipework onto floor

3. Bend and form two of the following types of pipe: ● carbon steel● stainless steel● copper

● brass● aluminium● plastic

4. Cut and prepare pipework using three of the following: ● hack saws● power saw● pipe/tube cutter

● de-burring reamers● abrasive discs

5. Bend and form pipe using four of the following methods:● bending springs● pipe bender

● pipe expander● heating methods

● swaging kit● fillers

6. Produce pipework forms that include three of the following: ● angular bends● offsets● bridge sets● expansion loops

● radii● external swaged ends● internal swaged ends

7. Produce pipe bends and forms which comply with one of the following quality and accuracy standards:● BS or ISO standards● customer standards and requirements ● company standards and procedures● specific system requirements


365

Unit No 74: Pipe Bending and Forming by Hand MethodsKnowledge statements:


1. The specific safety precautions to be taken when working with pipe bending and cutting equipment2. The specific personal protective equipment that needs to be worn when carrying out the pipe bending activities3. The hazards associated with the pipe bending activities (handling long pipe lengths, using bending equipment,

using heating equipment), and how they can be minimised4. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing6. Principles and methods of marking out pipework and the type of equipment used (direct marking, use of templates,

use of set wires)7. How to prepare the pipes in readiness for the marking out activities (visually checking for defects, cleaning the

materials, removing burrs and sharp edges)8. Methods of holding and supporting pipework during the marking out activities, and equipment that can be used9. Allowances that need to be made in the marking out, for bending or the assembly of the various fittings that will be

used10. The characteristics of the various materials that are to be used with regard to the bending operations, and why

some materials may require the addition of heat/hot air to aid the bending process11. The methods used to hand bend and form the pipe (including the use of bending springs, hand bending machines,

fillers, heating methods)12. How to produce the various bends required (such as angled bends, dog-leg sets, bridge sets and expansion loops)13. The reasons for incorporating expansion loops in a system, and where they should be positioned14. The tools and equipment used in the cutting, bending and forming process15. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


366





required)evidence typedate carry out activities during hand forming and bending (all)use correct issue of drawings /specifications/quality documentationcheck that bending/forming equipment is safe/usable conditionapply safe working practices return all tools/equipment to correct location on completion of activitiesleave work area in safe conditionmark out pipework using methods (two)direct marking using tapes/markersset-outs of pipework using templatesproducing set wiresset-outs of pipework onto floor bend and form pipes (two)carbon steelstainless steel cooperbrass aluminiumplasticcut and prepare pipework using (three)hack sawspower sawpipe/tube cutterde-burring reamersabrasive discsbend and form pipe using methods (four)bending springspipe benderpipe expanderheating methodsswaging kitfillersproduce pipework forms (three)angular bendsoffsetsbridge setsexpansion loopsradiiexternal swaged endsinternal swaged ends


367





required)evidence typedate produce pipe bends and forms which comply with standards (one)BS/ISO standards and procedurescustomer standards and requirementscompany standards and proceduresspecific system requirements


Candidate: Date:

Assessor: Date:


368

Unit No 75: Pipe Bending and Forming using Bending Machines

Unit Summary

This unit identifies the competencies you need to bend and form ferrous, non-ferrous and/or non-metallic pipe, using bending machines, in accordance with approved procedures. In producing pipe bends and forms, you will be expected to select and use a range of tools, forming equipment and techniques that are appropriate to the type of material and operations being performed.

Activities will include cutting the pipes to the required lengths using saws or pipe/cutting machines, bending pipes using hydraulic bending machines or power operated equipment such as presses, the use of heating techniques to aid the bending process, and the use of templates or set wires to check bend profiles. The pipework produced will have features that include angular bends, offsets, bridge sets and expansion loops.

Your responsibilities will require you to comply with organisational policy and procedures for the pipe bending and forming activities undertaken, and to report any problems with the equipment, materials or pipe bending activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying pipe bending and forming procedures. You will understand the pipe bending and forming activities, and their application, and will know about the pipe bending and forming equipment and techniques, in adequate depth to provide a sound basis for carrying out the activities, correcting faults, and ensuring the work output is completed to the required specification.

You will understand the safety precautions required when carrying out the pipe bending activities and using the associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.


369

Unit No 75: Pipe Bending and Forming using Bending MachinesPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Confirm that the equipment is set up correctly and is ready for use c. Manipulate the machine controls safely and correctly in line with operational proceduresd. Produce components to the required specificatione. Carry out quality sampling checks at suitable intervalsf. Deal promptly and effectively with problems within your control and report those that cannot be solvedg. Shut down the equipment to a safe condition on conclusion of the machining activities


You must:1. Carry out all the following activities during hand forming and bending:

● use the correct issue of drawings, specifications, job instructions and quality documentation● check that the bending machine and equipment is in a safe and usable condition● apply safe working practices at all times● return all tools and equipment to the correct location on completion of the activities● leave the work area in a safe condition

2. Mark out pipework using two of the following methods: ● direct marking using tapes and markers● set-outs of pipework using templates

● producing and using set wires● set-outs of pipework onto floor

3. Bend and form two of the following types of pipe: ● carbon steel● stainless steel● copper

● brass● aluminium● plastic

4. Cut and prepare pipework using two of the following: ● pipe cutting machine● power saw

● abrasive discs● gas cutting equipment

5. Bend and form pipe using two of the following methods: ● hand operated pipe bender● hydraulic pipe bending equipment

● heating methods● power operated equipment (presses)

6. Produce pipework forms that includes all of the following: ● angular bends● offsets

● bridge sets● expansion loops

7. Produce pipe bends and forms which comply with one of the following quality and accuracy standards: ● BS or ISO standards● customer standards and requirements ● company standards and procedures

specific system requirements


370

Unit No 75: Pipe Bending and Forming using Bending MachinesKnowledge statements:


1. The specific safety precautions to be taken when working with pipe bending and cutting equipment2. The specific personal protective equipment that needs to be worn when carrying out the pipe bending activities3. The hazards associated with the pipe bending activities (handling long pipe lengths, using power operated bending

equipment, using heating equipment), and how they can be minimised4. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing6. Principles and methods of marking out pipework, and the type of equipment used (direct marking, use of

templates, use of set wires)7. How to prepare the pipes in readiness for the marking out activities (visually checking for defects, cleaning the

materials, removing burrs and sharp edges)8. Methods of holding and supporting pipework during the marking out activities, and equipment that can be used9. Allowances that need to be made in the marking out, for bending or the assembly of the various fittings that will be

used10. The characteristics of the various materials that are to be used with regard to the bending operations, and why

some materials may require the addition of heat/hot air to aid the bending process11. The methods used to bend and form the pipe (including the use of hand bending machines, hydraulic bending

equipment, power operated equipment and heating methods)12. How to produce the various bends required (such as angled bends, dog-leg sets, bridge sets and expansion loops)13. The reasons for incorporating expansion loops in a system, and where they should be positioned14. The tools and equipment used in the cutting, bending and forming process15. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve



371


required)evidence typedate carry out activities during hand forming and bending (all)use correct issue of drawings /specifications/job instruction /quality documentation check the bending machine/ equipment is safe/usable conditionapply safe working practices return all tools/equipment to correct location on completion of activitysafe working area conditionmark out pipework using methods (two)direct marking using tapes /markersset-outs of pipework using templatesproducing/using set wiresset-outs of pipework on floorbend and form types of pipe (two)carbon steel stainless steelcopperbrassaluminiumplasticcut and prepare pipework using (two)pipe cutting machinepower sawabrasive discsgas cutting equipmentbend and form pipe using methods (two)hand operated pipe benderhydraulic pipe bending equipmentheating methodspower operated equipmentproduce pipework forms including (all)angular bendsoffsetsbridge setsexpansion loopsproduce pipe bends and forms which comply with standards (one)BS/ISO standards and procedurescustomer standards and requirementscompany standards and proceduresspecific system requirements


Candidate: Date:

Assessor: Date:

Unit No 76: Assembling Screwed Pipework


372

Unit No 76: Assembling Screwed Pipework

Unit Summary

This unit identifies the competencies you need to assemble screwed pipework, in accordance with approved procedures. In producing assemblies, you will be expected to select and use a range of equipment, hand tools and techniques appropriate to the operations being performed.

The assembly activities will include producing threads on the external ends of the pipe, using stocks and dies or threading machines, and joining the pipes using a range of fittings, which will include flanges and gaskets, straight couplings, elbows, tee pieces, reduction pieces and other fittings as appropriate to the application.

Your responsibilities will require you to comply with organisational policy and procedures for the assembly activities undertaken, and to report any problems with the equipment, materials or assembly activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying screwed pipework assembly procedures. You will understand the pipework assembly, and its application, and will know about the screwed pipework assembly process, components and materials used, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring that the work output is produced to the required specification.

You will understand the safety precautions required when working on pipework assembly activities and with the associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.


373

Unit No 76: Assembling Screwed PipeworkPerformance statements:



You must: 1. Carry out all of the following during the pipe assembly activities:

● use the correct pipe assembly drawings, specifications or job instructions● check all tools and equipment are in a safe and usable condition ● ensure the components and pipes used are free from foreign objects, dirt or other contamination● ensure appropriate techniques are used to assemble the system● ensure appropriate COSHH regulations are adhered to ● leave the work area in a safe condition

2. Cut pipes and produce screw threads on pipe ends, to include all of the following: ● cutting pipes to length with appropriate allowance for threading● selecting and setting up dies in stocks or threading machines● cutting threads on pipe ends to the appropriate length● checking the completed threads have the required fit

3. Assemble screwed pipework using six the following screwed fittings:straight couplingselbowstee piecesflanges

● reduction pieces ● valves● drain/bleeding devices● blanking caps

4. Produce assembled pipe work which contains three of the following features: ● angular bends ● offsets

● bridge sets● expansion loops

5. Assemble pipework using all the following methods and techniques: ● securing pipework supports to structures● fitting pipework supports● connecting pipe-to-pipe● hand tools

● connecting pipe-to-equipment● using gaskets, seals or jointing compounds● alignment/levelling equipment● torque loading of bolts

6. Produce pipework assemblies which comply with one of the following quality and accuracy standards: ● BS or ISO standards● customer standards and requirements ● company standards and procedures● specific system requirements


374

Unit No 76: Assembling Screwed PipeworkKnowledge statements:


1. The specific safety precautions to be taken when assembling screwed pipework2. The personal protective equipment that needs to be used when assembling screwed pipework3. The hazards associated with the pipework assembly activities (such as handling long lengths of pipe, using

pipe screwing machinery, handling sealing agents), and how they can be minimised4. How to use and extract information from engineering drawings and related specifications, to include symbols

and conventions to appropriate BS or ISO standards in relation to work undertaken 5. How to interpret first and third angle drawings, imperial and metric systems of measurement, work reference

points and system of tolerancing6. The preparation of pipework and fittings for the assembly operation (checking for damage, removing foreign

objects, dirt and swarf from bore of pipe, removing burrs)7. The range of pipe fittings that can be used, and how to identify them (straight connectors, elbows, tee pieces,

reduction pieces, flanged fittings, valves, blanking pieces/cap ends)8. How to determine the overall length of the pipework required, taking into account allowances for pipe fittings and

screwed connections9. How to produce screw threads on the pipe ends, and the tools and equipment that can be used (stocks and dies,

pipe threading machines)10. Methods used to seal screwed joints (such as tapes and sealing compounds)11. The use of flanges to connect pipes; use of gaskets; and torque loading of flange bolts12. How to identify the correct orientation of fittings with regard to flow13. The methods used to handle pipework assemblies14. The supporting methods that are used when assembling pipework, and the type of fittings that are used15. The tools and equipment used when assembling pipework16. The standards to be attained and company quality procedures17. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


375





required)evidence typedate carry out during pipe assembly activities (all)use correct pipe assembly drawings/specifications/job instructionscheck all tools/equipment are in safe/usable conditionensure components/pipes used are free from foreign objects/dirt/other contaminationensure appropriate techniques are used to assemble systemensure appropriate COSHH regulations are adhered toleave work area in safe conditioncut pipes and produce screw threads on pipe ends (all) cutting pipes to length appropriate with appropriate allowance for threadingselecting/setting up dies in stocks/threading machinescutting threads on pipe ends to appropriate lengthchecking completed threads have required fitassemble screwed pipework using fittings (six)straight couplingselbowstee piecesflangesreduction piecesvalvesdrain/bleeding devicesblanking capsproduce assembled pipework which contains features (all)angular bendsoffsetsbridge setsexpansion loopsassemble pipework using methods and techniques (all)securing pipework supports/structuresfitting pipework supportsconnecting pipe-to-pipehand toolsconnecting pipe-to equipmentusing gaskets/seals/ joints compoundsalignment/levelling equipmenttorque loading of bolts



376


required)evidence typedate produce pipework assemblies which comply with standards (one)BS/ISO standards and procedurescustomer standards and requirementscompany standards and proceduresspecific system requirements


Candidate: Date:

Assessor: Date:


377

Unit No 77: Assembling Small Bore Non-Ferrous Pipework

Unit Summary

This unit identifies the competencies you need to assemble small bore non-ferrous pipework, in accordance with approved procedures. In producing assemblies, you will be expected to select and use a range of equipment, hand tools and techniques appropriate to the operations being performed.

The assembly activities will include producing soldered joints, brazed joints and compression joints. The pipe assemblies produced will use a range of fittings which will include straight connectors, elbows, tee pieces, reduction pieces, tank connectors, tap connectors, valves and other fittings, as appropriate to the application.

Your responsibilities will require you to comply with organisational policy and procedures for the pipework assembly activities undertaken, and to report any problems with the equipment, materials or assembly activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying small bore non-ferrous pipework assembly procedures. You will understand the pipework assembly, and its application, and will know about the assembly and soldering/brazing process, pipe components and materials used, in adequate depth to provide a sound basis for carrying out the activities, correcting faults, and ensuring that the work output is produced to the required specification.

You will understand the safety precautions required when working on the pipework assembly activities and with the associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.


378

Unit No 77: Assembling Small Bore Non-Ferrous PipeworkPerformance statements:




● use the correct pipe assembly drawings, specifications or job instructions● ensure the components and pipes used are free from foreign objects, dirt or other contamination● check all tools are in a safe and usable condition ● ensure appropriate techniques are used to assemble the system● ensure appropriate COSHH regulations are adhered to ● leave the work area in a safe condition on completion of the activities

2. Cut pipes and assemble them, using three of the following methods: ● compression fittings ● snap-on/push fittings ● soldered fittings ● brazed fittings

3. Produce pipework assemblies which contain six of the following types of fittings: ● straight couplings● valves

● elbows● blanking caps

● tee pieces● pipe clips/supports

● reduction pieces

• drain/bleeding devices ● screwed fittings (tank, tap, pump, gauges)4. Produce assembled pipe work which contains two of the following features:

● angular bends ● offsets● bridge sets

5. Assemble pipework using six of the following: ● soft solder● silver solder

● flux● hand tools

● pipe cutters● gas torches

● sealing tapes, seals or compounds

6. Assemble pipework using all the following methods and techniques: ● securing pipework supports to structures● fitting pipework supports● connecting pipe-to-pipe● hand tools

● connecting pipe-to-equipment● using gaskets, seals or jointing compounds● alignment/levelling equipment● torque loading of bolts



379

Unit No 77: Assembling Small Bore Non-Ferrous PipeworkKnowledge statements:


1. The specific safety precautions to be taken when assembling small bore non-ferrous pipework2. The personal protective equipment that needs to be used when assembling pipework3. The hazards associated with the pipework assembly activities (handling long lengths of pipe, using gas torches and

brazing equipment, handling sealing agents and fluxes), and how they can be minimised4. How to use and extract information from engineering drawings and related specifications, to include symbols and

conventions to appropriate BS or ISO standards in relation to work undertaken5. How to interpret first and third angle drawings, imperial and metric systems of measurement, work reference



reduction pieces, screwed fittings, valves, blanking pieces/cap ends)8. The different types of fittings available, such as soldered fittings, compression fittings and push fit fittings9. How to determine the overall length of the pipework required, taking into account allowances for pipe fittings10. How to identify the correct orientation of fittings with regard to flow, and the consequences of incorrectly

orientating the fitting11. The methods used to prepare pipe ends and fittings for soldering or brazing, and why it is necessary to ensure that

these preparations are carried out12. The various types of soldered connectors available (such as solder ring types and capillary fittings)13. The methods used to solder the joints, and how to recognise when the fitting is correctly soldered on14. The precautions to be taken when using gas torches to form the joint, and the effect of overheating the joint15. The use of compression fittings; how the pipes are sealed; and the effects of over tightening the fittings16. The use of push-fit connectors, and their advantages and disadvantages17. Methods of supporting pipework, and the type of fittings that are used18. The tools and equipment used when assembling small bore pipework19. The standards to be attained and company quality procedures20. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


380





required)evidence typedate pipe assembly activities (all)use correct pipe assembly drawings/specifications/job instructionsensure components/pipes are free from foreign objects/ dirt/other contaminationcheck all tools are in safe usable conditionensure appropriate techniques are used to assemble systemensure appropriate COSHH regulations are adhered toleave work area in safe conditioncut pipes and assemble them using methods (three)compression fittingssnap-on/push fittingssoldered fittingsbrazed fittingsproduce pipework assemblies which contain fittings (six)straight couplingsvalvesdrain/bleeding deviceselbowsblanking capstee piecespipe clips/supportsscrewed fittingsreduction piecesproduce assembled pipe work which contains features (all)angular bendsoffsetsbridge setsassemble pipework using (six)soft soldersilver solderfluxhand toolspipe cuttersgas torchessealing tapes, seals or compoundsassemble pipework using methods and techniques (all)securing pipework supportsfitting pipework supportsconnecting pipe-to-pipehand toolsconnecting pipe-to equipmentusing gaskets, seals or jointing compoundstorque loading of boltsalignment/levelling


381





required)evidence typedate produce pipework assemblies which comply with standards (one)BS/ISO standards customer standards and requirementscompany standards and proceduresspecific system requirements


Candidate: Date:

Assessor: Date:


382

Unit No 78: Assembling Non- Metallic Pipework

Unit Summary

This unit identifies the competencies you need to produce assemblies in non-metallic pipework in accordance with approved procedures. In producing assemblies, you will be expected to select and use a range of equipment, hand tools and techniques appropriate to the operations being performed.

The assembly activities will include producing cemented/glued joints, compression joints and push-fit joints. The pipe assemblies produced will use a range of fittings, which will include straight connectors, elbows, tee pieces, reduction pieces, flanges, tank connectors, tap connectors, valves and other fittings, as appropriate to the application.

Your responsibilities will require you to comply with organisational policy and procedures for the pipework assembly activities undertaken, and to report any problems with the equipment, materials or assembly activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying non-metallic pipework assembly procedures. You will understand the pipework assembly, and its application, and will know about the assembly techniques, pipe components and materials used, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring that the work output is produced to the required specification.

You will understand the safety precautions required when working on the pipework assembly activities and with the associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.


383

Unit No 78: Assembling Non- Metallic PipeworkPerformance statements:




● use the correct pipe assembly drawings, specifications or job instructions● ensure the components and pipes used are free from foreign objects, dirt or other contamination● check all tools are in a safe and usable condition● ensure appropriate techniques are used to assemble the system● ensure appropriate COSHH regulations are adhered to ● leave the work area in a safe condition

2. Cut pipes and assemble them using all of the following methods: ● compression fittings ● snap-on/push fittings ● cemented/glued fittings

3. Produce pipework assemblies which contain six of the following types of fittings: ● straight couplings● valves

● elbows● blanking caps

● tee pieces● pipe clips/supports

● reduction pieces

• drain/bleeding devices● screwed fittings (tank, tap, pump, gauges)

4. Produce assembled pipe work which contains two of the following features: ● angular bends ● offsets● bridge sets

5. Assemble pipework using all the following methods and techniques:● securing pipework supports to structures● fitting pipework supports● connecting pipe-to-pipe● hand tools ● adhesives

● connecting pipe-to-equipment● using gaskets, seals or jointing compounds● alignment/levelling equipment● torque loading of bolts ● hot air/gas torches



384

Unit No 78: Assembling Non- Metallic PipeworkKnowledge statements:


1. The specific safety precautions to be taken when assembling non-metallic pipework2. The personal protective equipment that needs to be used when assembling non-metallic pipework3. The hazards associated with the pipework assembly activities (handling long lengths of pipe, using hot air/gas

torches, handling adhesives and sealing agents), and how they can be minimised4. How to use and extract information from engineering drawings and related specifications, to include symbols and

conventions to appropriate BS or ISO standards in relation to work undertaken5. How to interpret first and third angle drawings, imperial and metric systems of measurement, work reference



reduction pieces, tank fittings, valves, blanking pieces/cap ends)8. The different types of fittings available (such as cemented/glued fittings, compression fittings and push-fit fittings)9. How to determine the overall length of the pipework required, taking into account allowances for pipe fittings10. How to identify the correct orientation of fittings with regard to flow, and the consequences of incorrectly

orientating the fitting11. The methods used to prepare pipe ends and fittings when using adhesives, and why it is necessary to ensure that

these preparations are carried out12. The methods used to glue the joints, and how to recognise when the fitting is correctly secured13. The various adhesives and sealing compounds that are used on non-metallic pipework14. The precautions to be taken when using the adhesives and sealing compounds (adequate ventilation, away from

naked flames, avoiding skin contact)15. The precautions to be taken when using hot air/gas torches to form the joint, and the effect of overheating the joint16. The use of compression fittings; how the pipes are sealed; and the effects of over tightening the fittings17. The use of push-fit connectors, and their advantages and disadvantages18. Methods of supporting pipework and the type of fittings that are used.19. The tools and equipment used when assembling pipework20. The standards to be attained and company quality procedures21. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


385





required)evidence typedate carry out pipe assembly activities (all)use correct pipe assembly drawings/specifications/ job instructionsensure components/pipes are free from foreign objects /dirt/other contaminationcheck all tools are in safe and usable conditionensure appropriate techniques are used to assemble the systemensure appropriate COSHH regulations are adhered toleave work area in safe conditioncut pipes and assemble them using methods (three)compression fittingssnap-on/push fittingscemented/glued fittingsproduce pipework assemblies which contain fittings (six)straight couplingsvalvesdrain/bleeding deviceselbowsblanking capstee piecespipe clips/supportsscrewed fittingsreduction piecesproduce assembled pipework which contains features (all)angular bendsoffsetsbridge setsassemble pipework using methods and techniques (all)securing pipework supports to structuresfitting pipework supportsconnecting pipe-to-pipehand toolsadhesivesconnecting pipe to equipmentusing gaskets/seals/jointing compoundsalignment/levelling equipmenttorque loading of boltshot air/gas torches






386


evidence typedate produce pipework assemblies which comply with standards (one)BS/ISO standards customer standards and requirementscompany standards and proceduresspecific system requirements


Candidate: Date:

Assessor: Date:


387

Unit No 79: Preparing and Testing Pipework Systems

Unit Summary

This unit identifies the competencies you need to test ferrous, non-ferrous and non-metallic pipework systems, in accordance with approved procedures. You will be required to select appropriate tools and test equipment to be used, based on the pipework system and test procedures being carried out. In preparing and testing the pipework system, you will be expected to use a range of hand tools, test equipment and techniques which are important to the test procedures. These activities will include such things as purging equipment and materials, compressed air test rigs, pressure gauges, and leak repair equipment and materials.

Your responsibilities will require you to comply with organisational policy and procedures for the preparation and testing of the pipework, and to report any problems with the equipment, testing activities or installations tested that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying pipework preparation and testing activities. You will understand the pipework system being tested, and its application, and will know about the preparations required, equipment to be used and tests to be carried out, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the completed system performs to the required specification.

You will understand the safety precautions required when testing the pipework installation and with using the associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.


388

Unit No 79: Preparing and Testing Pipework SystemsPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the appropriate procedures for use of tools and equipment to carry out the required testsc. Set up and carry out the tests using the correct procedures and within agreed timescalesd. Record the results of the tests in the appropriate formate. Review the results and carry out further tests if necessary


You must:1. Carry out the following during the testing activities:

● use the correct test procedures and specifications● complete relevant test documentation● check all tools and test equipment are within calibration date● obtain clearance/authority to work on the installation ● ensure isolation procedures are followed and safe working distance procedures are set up● erect relevant warning notices or safety signs● ensure appropriate safety measures are taken to protect test personnel (guards, distance, incremental

pressure tests)2. Carry out tests on two of the following types of pipework installations:

● ferrous pipework ● small bore non-ferrous pipework ● non-metallic pipework3. Prepare the installation for testing by carrying out all of the following, as applicable to the system:

• checking security of all joints • purging or flushing the system (as appropriate) ● fitting appropriate blanking plugs/plates to exposed ends of pipe or equipment ● connecting an appropriate test source● fitting leak detection equipment and/or pressure gauges

4. Use one of the following types of test equipment: ● hydraulic test equipment● compressed air test equipment

● gas test equipment● water test equipment

5. Deal with all the following complexities: ● systems with no faults ● systems with faults ● systems with intermittent faults

6. During tests, use two of the following fault finding techniques: ● half split technique ● input/output technique ● six point technique

7. Carry out appropriate tests to include all of the following, as applicable to the system under test: ● filling system with appropriate test medium● venting air from the system ● applying test pressures in incremental stages● checking for leaks at each stage

● recording test results ● depressurising the system● draining down the system (where appropriate)

8. The quality and accuracy of the testing must meet one from: ● BS or ISO standards● customer standards and requirements ● company standards and procedures● specific system requirements


389

Unit No 79: Preparing and Testing Pipework SystemsKnowledge statements:


1. The specific safety precautions to be taken when carrying out test procedures on pipework systems2. The personal protective equipment that needs to be worn whilst carrying out the testing activities3. The hazards associated with the testing activities, and how they can be minimised4. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing6. The importance of pipework colour codes, and the reasons for using the correct type of pipe material7. The colour code standard used for identifying pipes, and why it is important8. The various pressure test methods used on ferrous, non-ferrous and non-metallic pipelines9. The importance of components being fitted in the correct relation to the direction of flow10. The reasons for purging and venting pipework systems, and the consequences of not purging the pipework system11. How to identify the fluids that can be used for flushing pipework systems, and what would be the consequences of

not flushing or of using the incorrect flushing agent12. Methods of testing the system, and the need to gradually increase pressure in the pipework system13. The methods used to isolate parts of the pipework system for testing, and how this can be achieved14. How the amount of test fluid for the pipework system is determined, and what problems would be caused if the

incorrect amount were used15. The factors that govern the choice of test equipment used in pressure testing of pipework systems, and the

importance of equipment being calibrated16. How the test pressures are determined, and the methods used to record pressure test results17. The reasons for maintaining test pressures for specific times18. How the results of the pressure test are analysed, and why this is important19. How pipework systems are depressurised, and what environmental precautions must be taken20. The procedures for recording and reporting test results to the relevant people21. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


390





required)evidence typedate carry out during testing activitiesuse correct test procedures/ specificationscomplete relevant test documentationcheck all tools/test equipment are within calibration dateobtain clearance/authority to work on the installationensure isolation procedures are followed/safe working distance procedures are set uperect relevant waning notices /safety signsensure appropriate safety measures are taken to protect personnelcarry out tests on pipework installation (two)ferrous pipeworksmall bore non-ferrous pipeworknon-metallic pipeworkprepare installation for testing by (all) checking security of all jointspurging/flushing the systemfitting appropriate blanking plugs/plates to exposed ends of pipe/equipmentconnecting an appropriate test sourcefitting leak detection equipment/pressure gaugesuse test equipment (one)hydraulic test equipmentcompressed air test equipmentgas test equipmentwater test equipmentdeal with complexities (all)systems with no faultssystems with faultssystems with intermittent faultsduring tests, use fault finding techniques (two)half split techniqueinput/output techniquesix point technique






391

required)evidence typedate carry out appropriate test, as applicable to system under test (all)filing system with appropriate test mediumventing air from systemtest pressures in incremental stageschecking leaks at each stagerecording test resultsdepressurising the system draining down the systemthe quality and accuracy must meet (one)BS/ISO standards customer standards and requirementscompany standards and proceduresspecific system requirements


Candidate: Date:

Assessor: Date:


392

Unit No 80: Producing Socket and Flange Fillet Welded Joints in Pipe using a Manual Welding Process

Unit Summary

This unit identifies the competencies you need to produce socket and flange fillet welded joints in pipe, using a manual welding process, such as MMA, MIG, MAG, TIG, flux cored wire, plasma or gas welding equipment, in accordance with instructions and/or approved welding procedures. You will be required to check that all the workholding equipment and manipulating devices required are available and in a usable condition. You will be expected to check the welding equipment to ensure that all the leads/cables, hoses and wire feed mechanisms are securely connected and free from damage.

In preparing to weld, you will need to set and adjust the welding conditions, in line with the instructions or welding procedure specification. You must operate the equipment safely and correctly, and make any necessary adjustments to settings, in line with your permitted authority, in order to produce the welded joints to the required specification. You will be required to demonstrate your capability to produce the fillet welds to the required quality, and this could be through tests according to BS 4872 or EN 287.

Your responsibilities will require you to comply with organisational policy and procedures for the welding activities undertaken, and to report any problems with the welding equipment or welding activities that you cannot resolve, or are outside your permitted authority, to the relevant people. You will be expected to work to instructions, taking personal responsibility for your own actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will be sufficient to provide a sound basis for your work, and will provide an understanding of how the particular welding process works. You will know about the equipment, materials and consumables, in adequate depth to provide a sound background for the welding operations to be performed, and for ensuring the work output is produced to the required specification.

You will understand the safety precautions required when working with the welding equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.


393

Unit No 80: Producing Socket and Flange Fillet Welded Joints in Pipe using a Manual Welding ProcessPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the relevant joining procedure and job instructionsc. Check that the joint preparation complies with the specificationd. Check that joining and related equipment and consumables are as specified and fit for purposee. Make the joints as specified using the appropriate thermal joining techniquef. Produce joints of the required quality and of specified dimensional accuracyg. Shut down the equipment to a safe condition on completion of joining activitiesh. Deal promptly with excess and waste materials and temporary attachments, in line with approved and agreed proceduresi. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must:1. Set up, check, adjust and use welding and related equipment for one of the following welding processes:

Manual Metal ArcMIG/MAGTIG

Cored wirePlasmaGas welding

2. Use consumables appropriate to the material and application, to include either of the following: two types of electrode from:rutilebasiccellulosic nickel alloyaluminium

ortwo types of filler wire from different material groups

3. Produce socket and flange fillet welded joints in one of the following: small bore pipe (50mm outside diameter or less)large bore pipe (above 50mm outside diameter)

4. Weld joints according to BS EN287, in good access situations, in four of the following positions: • flat (PA) rotating

horizontal vertical (PB) fixedhorizontal vertical (PB) rotating

vertical upwards (PF) fixedvertical down (PG) fixedhorizontal overhead (PD) fixed

5. Produce welded pipes which: • achieve minimum weld quality requirements applicable to fillet welds equivalent to those given in the relevant

European / International Standards (eg, EN 25817/ISO 5187 and EN 30042/ISO 10042) as required by the application standard or specification

• meet the required dimensional accuracy within specified tolerance


394

Unit No 80: Producing Socket and Flange Fillet Welded Joints in Pipe using a Manual Welding ProcessKnowledge statements:


1. The safe working practices and procedures to be observed when working with the selected welding equipment (general workshop and site safety, appropriate personal protective equipment, fire prevention, protecting other workers from arc eye, safety in enclosed/confined spaces, fume control, accident procedure, statutory regulations, risk assessment procedures and COSHH regulations)

2. The correct handling and storage of gas cylinders (manual handling and use of cylinder trolley, leak detection procedures, relevant BCGA codes of practice, cylinder identification, gas pressures, cylinder and equipment safety features, emergency shutdown procedures)

3. The hazards associated with the selected welding process (live electrical components, poor earthing, arc radiation, fumes and gases, gas supply leaks, spatter, hot slag and metal, elevated working, enclosed spaces, slips, trips and falls), and how they can be minimised

4. The manual welding process selected, and an awareness of the different types of welding equipment (basic principles of fusion welding, AC and DC power sources, ancillary equipment, power ranges, care of equipment, terminology used in welding, flame setting)

5. Extracting information required from drawings and welding procedure specifications (interpretation of welding symbols, scope, content and application of the welding procedure specification)

6. The consumables associated with the chosen welding process (types of electrodes and or filler metal and application, types of shielding gas and their application, gas supply and control, correct storage and drying of electrodes and filler wire)

7. The types and features of welded joints in pipe (fillet and butt welds, single and multi-run welds, welding positions, weld quality)

8. Methods of setting up and restraining the joint, to achieve correct location of components and control of distortion (edge preparation, use of jigs and fixtures, manipulators and positioners, tack welding size and spacing in relationship to material thickness and component size, use of temporary attachments, pre-setting)

9. Preparing the welding equipment, and checks that need to be made to ensure that it is safe and ready to use (electrical connections, earthing arrangements, equipment calibration, setting welding parameters)

10. The techniques of operating the welding equipment to produce a range of joints in the various joint positions (fine tuning parameters, correct manipulation of the welding gun or electrode, safe closing down of the welding equipment)

11. The importance of complying with job instructions and the welding procedure specification12. Problems that can occur with the welding activities, and how these can be overcome (causes of distortion and

methods of control, effects of welding on materials, sources of weld defects and methods of prevention)13. The organisational quality systems used and weld standards to be achieved; weld inspection and test procedures

used, including visual and non-destructive tests14. Personal approval tests and their applicability to your work15. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


395





required)evidence typedate set up, check, adjust and use welding related equipment (one)manual metal arcMIG/MAGTIGcored wireplasmagas weldinguse consumables appropriate to the material and application (either)rutilebasiccellulosicnickel alloyaluminiumtwo types of filler wire from different material groupsproduce socket and flange fillet welded joints (one)small bore pipelarge bore pipeweld joints according to BS EN287, in good access situations (four)flat (PA) rotatinghorizontal vertical (PB) fixedhorizontal vertical (PB) rotatingvertical upwards (PF) fixedvertical down (PG) fixedhorizontal overhead (PD) fixedproduce welded pipes which achieve minimum weld quality requirements to fillet welds equivalent to relevant European/International standardsmeet required dimensional accuracy within specified tolerance


Candidate: Date:

Assessor: Date:


396

Unit No 81: Producing Composite Mouldings using Pre-Preg Laminating Techniques

Unit Summary

This unit identifies the competencies you need to produce composite mouldings (moulds, components, splashes, jigs) using pre-preg laminating techniques, in accordance with approved procedures. You will be required to use appropriate drawings, specifications and documentation to produce various mouldings, using the correct pre-preg laminating production techniques.

You will be expected to prepare a range of tooling, apply release agents, and prepare composite materials. You will produce a range of composite mouldings, incorporating a variety of features and using a range of techniques and processes. Mouldings produced will include laminates and sandwich structures, using a range of resin, fibre and core materials.

Your responsibilities will require you to comply with organisational policy and procedures for the production activities undertaken, and to report any problems with the production activities, equipment or materials that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying pre-preg laminating techniques and procedures. You will understand the production techniques used, and their application, in adequate depth to provide a sound basis for carrying out the activities, correcting faults, and ensuring the work output is to the required specification.

You will understand the safety precautions required when carrying out the moulding activities and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.


397

Unit No 81: Producing Composite Mouldings using Pre-Preg Laminating TechniquesPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the correct component drawing or any other related specifications for the component to be producedc. Determine what has to be done and how this will be achievedd. Obtain and prepare the appropriate tools, equipment and materialse. Carry out the moulding or laying-up activities using the correct methods and techniquesf. Produce components to the required specification g. Check that all the required operations have been completed to specificationh. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must:1. Carry out all of the following activities during the moulding activities:

• use the correct issue production documentation (drawings, manuals, specifications, job cards)• use relevant health and safety documentation (material data sheets, COSHH sheets, risk assessments)• use the correct tools and equipment for the activity, and ensure they are safe to use and suitably stored• keep the work area in a safe condition

2. Carry out all the following activities when preparing production tooling: • check tooling is correct and complete• clean tooling and remove resin build-ups• check for surface defects

• correctly apply sealers/release agents• clean and store tooling suitably after use

3. Carry out all the following activities to prepare materials for production: • obtain correct materials for the activity• thaw material removed from freezer storage • identifying defects in pre-preg materials• check materials are fit for purpose and in life

• check availability of ancillary materials required• cut materials to correct shape and orientation• check materials when provided in kit form• identify and protect materials in the work area

4. Produce a range of mouldings using techniques for four of the following types of production tools:• metal• wet lay-up

• glass pre-preg• tooling block

• carbon pre-preg• female tooling

• male tooling• multi-part tools

• matched tooling• closed tooling

5. Produce a range of mouldings incorporating two of the following in the lay-up:• butt joins• overlap joins

• staggered joins• orientated plies

• inverted plies• inserts

6. Produce a range of mouldings incorporating five of the following shape features: • internal corners• external corners

• double curvature• concave surface

• convex surfaces• return surfaces

• joggle details• nett edges

7. Produce a range of mouldings using four of the following methods: • production of ply templates• nesting of ply templates• vacuum de-bulk

• pressure de-bulk• intensifiers• shaped locators

• joining boards• loose tooling• others

8. Produce a range of mouldings using techniques for one type of resin from: • epoxy • phenolic • bismaleimide • cyanate ester


398

9. Produce a range of mouldings using techniques for two types of fibre from: • polyethylene • glass • aramid • carbon

10. Produce a range of mouldings using techniques for two types of reinforcement from: • continuous • uni-directional • braids • woven • multi-axis • tapes

11. Produce a range of mouldings using techniques for two types of core materials from: • wood• syntactic core

• expanding core• foam

• nomex honeycomb • aluminium honeycomb

12. When using core materials, use three of the following methods: • core templates• pre-shaping core• core chamfers

• peel plies• adhesive/resin films

• core splicing• edge filling

• single stage curing• multi-stage curing

13. Using one of the following for applying temperature during the cure cycle: • oven • heated tools/moulds • autoclave • heated press

14. Using one of the following for applying pressure during the cure cycle: • pressure bags • vacuum bags • thermal mould expansion • fibre tensioning

15. Where vacuum bags are used, use four of the following processes/methods: • check vacuum integrity• use of vacuum fittings• surface bagging

• envelope bagging• pleats and tucks• multi-part envelope bags

• internal bagging• through-tube bagging• reusable bagging

16. Produce a range of mouldings which comply with one of the following standards: • ISO 9000 Quality Assurance procedures• customer standards and requirements• company standards and procedures


399

Unit No 81: Producing Composite Mouldings using Pre-Preg Laminating Techniques



1. Health and safety precautions to be taken, and procedures used, when working with composite materials, consumables, tools and equipment in the specific work area

2. The hazards associated with composite materials, consumables, tools and equipment, and how to minimise these in the work area

3. Protective equipment that is needed for personal protection and, where required, the protection of others4. The application of COSHH regulations in relation to the storage, use and disposal of composite materials and

consumables5. How to use and extract information from engineering drawings and related specifications, to include


reference points and system of tolerancing7. Quality procedures used in the workplace to ensure production control (in relation to currency, issue,

meeting specification etc.) and the completion of such documents8. Conventions and terminology used for pre-preg laminating techniques (eg, material orientation, material

identification, material templates, ply lay-up, pressure plates, vacuum bagging, cure cycles, exotherm etc.)9. Different types of resin systems, fibres, reinforcements, and their merits10. Building up laminates, including orientation and balance of plies to minimise spring and distortion in

composite mouldings11. Different core, insert and filler materials, and their merits12. The visual identification of both raw and finished composite materials13. Identification of materials by product codes14. Different types of production tooling used for producing composite mouldings, and their merits15. The identification and rectification of defects in production tooling16. Methods of preparation for patterns, moulds and tooling, including the correct selection and use of surface

sealers and release agents17. The correct methods of storage, thawing and handling of pre-preg materials, including monitoring

temperature, storage life and out-life18. Methods used in the application of pre-preg materials to tooling surfaces, including methods of tailoring and

cutting19. Correct methods of storage and handling of ancillary and consumable materials20. Selection and use of ancillary and consumable materials (release films, breather fabrics, bagging films, tapes

etc.) to meet performance requirements such as temperature and compatibility21. Tools and equipment used in the pre-preg laminating activities, and their care, preparation and control

procedures22. Problems that can occur during the lay-up process, including modifications to the ply lay-up, and defects

such as contamination and distortion23. How modifications and defects can be overcome during the pre-preg laminating activity24. Cure cycles, including temperature and pressure ramps, dwell times, post curing25. The need for monitoring the cure cycle using thermocouples, probes, chart recorders and data logs26. Procedures and methods used for removing mouldings from production tooling27. The identification of defects in the composite moulding, such as de-lamination, voids, contaminants etc28. The care and safe handling of production tooling and composite mouldings throughout the production cycle29. The production controls used in the work area, and actions to be taken for unaccounted items30. How the composite moulding relates to its own quality documents, and the production tooling used31. The extent of your own responsibility and whom you should report to if you have problems that you cannot

resolve


400





required)evidence typedate carry out activities during the moulding activities (all)use correct issue production documentationuse relevant health & safety documentationuse correct tools and equipment, ensure they are safe to use/suitably stored keep work area in safe conditioncarry out activities when preparing production tooling (all)check tooling is correct and completeclean tooling and remove resin build upscheck for surface defectscorrectly apply sealers/ release agentsclean and store tooling suitably after usecarry out activities to prepare materials for production (all)obtain correct materialsthaw material removed from freezer storageidentifying defects in pre-preg materialscheck materials are fit for purpose and in lifecheck availability of ancillary materials requiredcut materials to correct shape/orientationcheck materials when provided in kit formidentify and check materialsproduce a range of mouldings using techniques for types of production tools (four)metalwet lay-upglass pre-pregtooling blockcarbon pre-pregfemale toolingmale toolingmulti-part toolsmatched toolingclosed toolingproduce a range of mouldings incorporating the following in the lay-up (two)butt joinsoverlap joinsstaggered joinsorientated joinsinverted pilesinserts






401


evidence typedate produce a range of mouldings incorporating the following shape features (five)internal cornersexternal cornersdouble curvatureconcave surfaceconvex surfacereturn surfacejoggle detailsnett edgesproduce a range of mouldings using methods (four)production of ply templatesnesting of ply templatesvacuum de-bulkpressure de-bulkintensifiersshaped locatorsjoining boardsloose toolingothersproduce a range of mouldings using techniques (one)epoxyphenolicbismaleimidecyanate esterKnowledge and understanding reference:

Candidate: Date:

Assessor: Date:


402

Unit No 82: Producing Composite Mouldings using Wet Lay-up Techniques

Unit Summary

This unit identifies the competencies you need to produce composite mouldings (moulds, components, splashes, jigs) using wet lay-up techniques, in accordance with approved procedures. You will be required to use appropriate drawings, specifications and documentation to produce various mouldings using the correct wet lay-up production techniques.

You will be expected to prepare a range of tooling, apply release agents and prepare composite materials. You will produce a range of composite mouldings, incorporating a range of features and using a range of application methods. Mouldings produced will include laminates and sandwich structures, using a range of resin, fibre and core materials.

Your responsibilities will require you to comply with organisational policy and procedures for the production activities undertaken, and to report any problems with the production activities, equipment or materials that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying composite moulding wet lay-up techniques and procedures. You will understand the production techniques used, and their application, in adequate depth to provide a sound basis for carrying out the activities, correcting faults, and ensuring the work output is produced to the required specification.

You will understand the safety precautions required when carrying out the wet lay-up moulding activities and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.


403

Unit No 82: Producing Composite Mouldings using Wet Lay-up TechniquesPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and

guidelinesb. Follow the correct component drawing or any other related specifications for the component

to be producedc. Determine what has to be done and how this will be achievedd. Obtain and prepare the appropriate tools, equipment and materialse. Carry out the moulding or laying-up activities using the correct methods and techniquesf. Produce components to the required specification g. Check that all the required operations have been completed to specificationh. Deal promptly and effectively with problems within your control and report those that cannot

be solved


You must:1. Carry out all of the following during the moulding activities:

• use the correct issue production documentation (drawings, manuals, specifications, job cards)• use relevant health and safety documentation (material data sheets, COSHH sheets, risk assessments)• use the correct tools and equipment for the activity and ensure they are safe to use• keep the work area in a safe condition

2. Carry out all the following activities when preparing production tooling: • check tooling is correct and complete• clean tooling and remove resin build-ups• check for surface defects

• correctly apply sealers/release agents• clean and store tooling suitably after use

3. Carry out all the following activities to prepare materials for production: • obtain correct materials for the activity• check materials are fit for purpose and in

life• cut materials to correct size and shape

• check quantities of resins etc. are available• identify and protect materials in the work area• check correct measure and mix of resin/ catalyst

4. Produce a range of mouldings using three of the following application techniques: • spray application of

fibre/resin• application of a gel coat • brush application of

fibre/resin

• roller application of fibre/resin• removal of voids and air pockets

• use of vacuum bagging• use of bleed plies

5. Produce a range of mouldings incorporating two of the following in the lay-up:

• feathered joins

• overlap joins

• orientated plies

• inserts • fixtures • butt joins

6. Produce a range of mouldings incorporating three of the following shape features: • internal corner• external corner

• double curvature• concave surface

• convex surface• vertical surface

7. Produce a range of mouldings using techniques for one type of resin from: • polyester • vinyl ester • epoxy • phenolic

8. Produce a range of mouldings using techniques for one type of fibre from: • polyethylene • glass • aramid • carbon

9. Produce a range of mouldings using techniques for two types of reinforcement from: • roving • braids • tapes • chopped strand • continuous

filament• woven

10. Produce a range of mouldings using techniques for one type of core material from: • wood • coremat • foam • honeycomb

11. Produce a range of mouldings which comply with one of the following standards: • ISO 9000 Quality Assurance procedures• customer standards and requirements

• company standards and procedures


404

Unit No 82: Producing Composite Mouldings using Wet Lay-up TechniquesKnowledge statements:


1. Health and safety precautions to be taken and procedures used when working with composite materials, consumables, tools and equipment in the specific work area



consumables5. How to use and extract information from engineering drawings and related specifications, to include symbols


reference points and system of tolerancing7. Quality procedures used in the workplace to ensure production control (in relation to currency, issue,

meeting specification etc.) and the completion of such documents8. Conventions and terminology used for wet lay-up techniques (eg, resin and fibre weights/volumes, material

orientation, material identification, material tailoring, mixing ratios, gel times, exotherm, bleed plies etc)9. Different types of resins, fibres, reinforcement, and their merits10. The visual identification of both raw and finished composite materials11. Different types of production tooling used for producing composite mouldings12. The identification and rectification of defects in production tooling13. Methods of preparation for patterns, moulds and tooling, including the correct use of surface sealers and

release agents14. Methods for handling and preparing the reinforcing fibres15. Estimation of resin volume/weight required to wet-out the reinforcing fibres16. Mixing ratios for gel coats, resins and catalysts, and the associated working times17. The methods used in the application of the resin/fibre during the lay-up activity18. Tools and equipment used in the lay-up activities and their care, preparation and control procedures19. Problems that can occur during the lay-up process, including defects such as contamination, resin/fibre rich

areas, and distortion20. How defects can be overcome during the lay-up activity21. Procedures and methods used for removing mouldings from production tooling22. The identification of defects in the composite moulding, such as de-lamination, voids, contaminants etc23. The care and safe handling of production tooling and composite mouldings throughout the production cycle24. The production controls used in the work area, and actions to be taken for unaccounted items25. How the composite moulding relates to its own quality documents and the production tooling used26. The extent of your own responsibility and whom you should report to if you have problems that you cannot

resolve


405





required)evidence typedate carry out all the following during moulding activities (all)use the correct issue production documentationuse relevant health and safety documentationuse correct tools and equipment/ensure they are safe to usekeep work area in safe conditioncarry out activities when preparing production tooling (all)check tooling is correct/completeclean tooling and remove resin build upcheck for surface defectscorrectly apply sealers/ release agentsclean and store tooling suitablycarry out activities to prepare materials for production (all)obtain correct materialscheck materials are fit for purpose and in lifecut materials to correct size/ shapecheck quantities of resinsidentify and protect materialscheck correct measure/mix of resin/catalystproduce a range of mouldings using application techniques (three)spray application of fibre/resinapplication of a gel coatbrush application of fibre/resinroller application of fibre/resinremoval of voids and air pocketsuse of vacuum bagginguse of bleed pliesproduce a range of mouldings incorporating them in the lay-up (three)feathered joinsoverlap joinsorientated pliesinsertsfixturesbutt joinsproduce a range of mouldings incorporating shape features (three)internal cornerexternal cornerdouble curvatureconcave surfaceconvex surfacevertical surfaceproduce a range of mouldings using techniques for resin from (one)polyestervinyl esterepoxyphenolic



406


required)evidence typedate produce a range of mouldings using techniques for fibre from (one)polyethyleneglassaramidcarbonproduce a range of mouldings using techniques for reinforcement from (two)rovingbraidstapeschopped strandcontinuous filamentwovenproduce a range of mouldings using techniques for core material from (one)woodcorematfoamhoneycombproduce a range of mouldings which comply with standards (one)ISO 9000 quality assurance procedurescustomer standards and requirementscompany standards and procedures


Candidate: Date:

Assessor: Date:


407

Unit No 83: Producing Composite Assemblies

Unit Summary

This unit identifies the competencies you need to produce composite assemblies from composite components and non-composite components, in accordance with approved procedures. You will be required to use appropriate drawings, specifications and documentation to produce composite assemblies, using the correct techniques. You will produce a range of composite assemblies, incorporating a range of features and using a range of techniques and processes.

Your responsibilities will require you to comply with organisational policy and procedures for the assembly activities undertaken, and to report any problems with the assembly activities, equipment or materials that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying composite assembly techniques and procedures. You will understand the composite assembly techniques used, and their application, in adequate depth to provide a sound basis for carrying out the activities, correcting faults, and ensuring the finished assembly is to the required specification.

You will understand the safety precautions required when carrying out the assembly activities and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.


408

Unit No 83: Producing Composite Assemblies Performance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the relevant instructions, assembly drawings and any other specificationsc. Ensure that the specified components are available and that they are in a usable conditiond. Use the appropriate methods and techniques to assemble the components in their correct positionse. Secure the components using the specified connectors and securing devicesf. Check the completed assembly to ensure that all operations have been completed and the finished assembly meets

the required specificationg. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must:1. Carry out all of the following activities during the assembly activities:

• use the correct issue production documentation (drawings, manuals, specifications, job cards)• use relevant health and safety documentation (material data sheets, COSHH sheets, risk assessments)• use the correct tools and equipment for the activity and ensure they are safe to use and suitably stored• keep the work area in a safe condition

2. Carry out all the following activities when preparing for the assembly activity: • check mouldings are correct and complete• check for any defects in the mouldings• check components are correct and complete• check availability of ancillary materials required

• select correct equipment for the activity• check equipment is suitable for use• check for any defects in the components

• identify and protect the moulding and components in the work area3. Produce two of the following types of composite assembly:

• trial assemblies • one-off assemblies • batch assemblies • assembly line4. Produce assemblies that incorporate four of the following features:

• loose fit tolerances • close fit tolerances

• non-permanent fixing• shape location

• joggle joins• permanent fixing

• return joins• overlap joins

5. Produce composite assemblies that require four of the following methods to be used: • fettling• pinning

• clamping• trial fitting

• aligning• assembly jigs

• assembly sequences

6. Produce composite assemblies that use three of the following joining methods: • thread inserts• quick-release fasteners

• mechanical fasteners • anchor nuts • rivets

7. Composite components must include three of the following: • trim• closing panels

• body panels• tubes

• structural• aerodynamic

• core materials • sections

• inserts • housings

8. Non composite components must include three of the following types: • brackets • fixtures • fittings • trim • tapes • memory foam • films

9. Produce a range of assemblies which comply with one of the following standards: • ISO 9000 Quality Assurance procedures• customer standards and requirements• company standards and procedures


409

Unit No 83: Producing Composite Assemblies Knowledge statements:





consumables5. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing7. Quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting

specification etc.) and the completion of such documents8. Conventions and terminology used for assembly activities (eg, metric and imperial threads, rivet specifications,

clearances, types of fittings)9. The types of component trimming/cutting methods and preparation methods available10. The visual identification of cured composite materials11. Assembly operations and their sequence12. Methods for handling composite assemblies throughout the assembly activities13. The identification and rectification of defects in composite assemblies14. Tools and equipment used in assembly activities, and their care, preparation and control procedures15. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


410





required)evidence typedate carry out activities during assembly activities (all)use correct issue production documentationuse relevant health and safety documentationuse correct tools and equipment/ensure they are safe to use/suitably storedkeep work area in safe conditioncarry out activities when preparing assembly activity (all)check mouldings are correct and completecheck for any defects in mouldingscheck components are correct and completecheck availability of ancillary materials requiredidentify and protect moulding and components in the work areaselect correct equipment for the activitycheck equipment is suitable for usecheck for any defects in componentsproduce types of composite assembly (two)trial assembliesone off assembliesbatch assembliesassembly lineproduce assemblies that incorporate features (four)loose fit tolerancesclose fit tolerancesnon-permanent fixingshape locationjoggle joinspermanent fixingreturn joinsoverlap joinsproduce composite assemblies that require methods to be used (four)fettling clampingaligningassembly sequencespinningtrial fittingassembly jigs


411





required)evidence typedate produce composite assemblies that use joining methods (three)thread insertsquick release fastenersmechanical fastenersanchor nutsrivetscomposite components must include (three)trimclosing panelbody panelstubesstructuralaerodynamiccore materialssectionsinsertshousingsnon composite components must include the following types (three)bracketsfixturesfittingstrimtapesmemory foamfilmsproduce a range of assemblies which comply with standards (one)ISO 9000 quality assurance procedurescustomer standards and requirementscompany standards and procedures


Candidate: Date:

Assessor: Date:


412

Unit No 84: Bonding Composite Mouldings

Unit Summary

This unit identifies the competencies you need to bond composite mouldings (cured panels, moulds, components and jigs), in accordance with approved procedures. You will be required to use appropriate drawings, specifications and documentation to bond advanced composites materials, using the correct techniques.

You will produce a range of bonded composite mouldings, incorporating a variety of features and using a range of techniques and processes. Bonded mouldings produced will include a range of resin, fibre and adhesive materials.

Your responsibilities will require you to comply with organisational policy and procedures for the bonding activities undertaken, and to report any problems with the bonding activities, equipment or materials that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying composite bonding techniques and procedures. You will understand the bonding techniques used, and their application, in adequate depth to provide a sound basis for carrying out the activities, correcting faults, and ensuring the work produced is to the required specification.

You will understand the safety precautions required when carrying out the composite bonding activities and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.


413

Unit No 84: Bonding Composite MouldingsPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the relevant bonding procedure specification and job instructionsc. Check that the materials to be bonded and bonding agents comply with the specificationd. Correctly prepare the parent materials and bonding agents in line with the bonding specificatione. Carry out the bonding operations using the specified processes and techniques to position and bond the materials in their correct locations f. Ensure that any equipment used to maintain surface contact during the bonding activities is set up and used correctlyg. Achieve bonds of the required quality and within the specified dimensional accuracy h. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must:1. Carry out all of the following during the bonding activities:


2. Carry out all the following activities when preparing for the bonding activity: • check mouldings are correct and complete• check for any defects in the mouldings• check bonding materials are within life

• check availability of ancillary materials required• select correct equipment for the activity• check equipment is suitable for use

• identify and protect the moulding and bonding materials in the work area• check bonding materials are correct and complete

3. Bond composite mouldings using techniques for two of the following:• one-part pastes • two-part pastes • film adhesives • syntactic films

4. Prepare bonding surfaces using four of the following methods: • peel plies• templates

• abrading• bead blasting

• water cleaning• solvent cleaning

• dry fitting• acid etching

• priming• surface masks

5. When bonding composite mouldings, use three of the following methods: • dry fitting• bonding sequences• shimming materials

• mixing adhesives• wetting-out by brush• applicator gun

• laying film adhesives• oven curing• heated press

6. During curing, retain the bond using two of the following: • weighting down• bonding jigs

• pinning joins • clamping • press • vacuum bagging

7. Bond composite mouldings using techniques for two of the following: • sandwich panels • butt joins • overlap joins • joggle joins • return joins

8. Bond composite mouldings using techniques for two of the following: • flat surfaces • shaped surfaces • internal surfaces • external surfaces

9. Use techniques for bonding three of the following materials to the composite moulding: • other composites • metals • ceramics • plastics • wood-based materials

10. Bond composite mouldings using adhesives suitable for two of the following resin types: • polyester • epoxy • phenolic • bismaleimide • cyanate ester • vinyl ester

11. Bond composite mouldings using adhesives suitable for two of the following fibre types: • polyethylene • glass • aramid • carbon • other specific types

12. Bond a range of mouldings which comply with one of the following standards: • ISO 9000 Quality Assurance procedures• Customer standards and requirements• Company standards and procedures


414

Unit No 84: Bonding Composite MouldingsKnowledge statements:








specification etc.) and the completion of such documents8. Conventions and terminology used for bonding (eg, gel points, cure times, bond thickness, bond strength, peel

strength)9. Different types of composite resin systems, fibres, reinforcements, and their merits10. Different bonding agents, and their merits11. Correct methods of storage and handling of bonding agents12. Methods of preparation for bonding different materials13. Mixing procedures and ratios for two-part pastes, and the associated working times14. Methods of application for different bonding agents15. Methods of retaining the bond during curing, and their merits16. Tools and equipment used in bonding activities, and their care, preparation and control procedures17. The identification and rectification of bond defects18. Problems that can occur during the bonding process, including defects such as contamination and distortion19. How defects can be overcome during the bonding activity20. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


415





required)evidence typedate following during the bonding activities (all)use correct issue production documentationuse relevant health and safety documentationuse the correct tools and equipment/ensure they are safe to use/suitably storedkeep work area in safe conditionactivities when preparing for bonding activity (all)check mouldings are correct and completecheck for any defects in mouldingscheck bonding materials are within lifecheck availability of ancillary materials requiredidentify and protect moulding/ bonding materials check bonding materials are correct and completecheck availability of ancillary materialselect correct equipment for activitycheck equipment is suitablebond composite mouldings using techniques (two)one-part pastestwo-part pastesfilm adhesivessyntactic filmsprepare bonding surfaces using methods (four)peel pliestemplatesabradingbead blastingwater cleaningsolvent cleaningdry fittingacid etchingprimingsurface maskswhen bonding composite mouldings use methods (three)dry fittingbonding sequencesshimming materialsmixing adhesiveswetting-out by brushapplicator gunlaying film adhesivesoven curingheated press


416





required)evidence typedate during curing, retain the bond using the following (two)weighting downbonding jigspinning joinsclamping pressvacuum baggingbond composite mouldings using techniques (two)sandwich panelsbutt joinsoverlap joinsjoggle joinsreturn joinsbond composite mouldings using techniques (two)flat surfacesshaped surfacesinternal surfacesexternal surfaces


Candidate: Date:

Assessor: Date:


417

Unit No 85: Repairing Composite Mouldings

Unit Summary

This unit identifies the competencies you need to repair composite mouldings (cured panels, moulds, components and jigs), in accordance with approved procedures. You will be required to use appropriate drawings, specifications and documentation to bond advanced composites materials, using the correct techniques.

You will be expected to identify the method of repair to be used and select suitable repair materials. You will repair a range of composite mouldings with various defects using a range of methods. Mouldings repaired will include a range of resin and fibre materials.

Your responsibilities will require you to comply with organisational policy and procedures for the repair activities undertaken, and to report any problems with the repair activities, equipment or materials that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying composite moulding repair procedures. You will understand the repair techniques used, and their application, in adequate depth to provide a sound basis for carrying out the activities to the required specification.

You will understand the safety precautions required when carrying out the repair activities and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.


418

Unit No 85: Repairing Composite Mouldings Performance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the relevant specifications for the component to be repairedc. Prepare the component for repaird. Carry out the repairs within agreed timescale using approved materials and components and methods and procedurese. Ensure that the repaired component meets the specified operating conditionsf. Produce accurate and complete records of all repair work carried out


You must:1. Carry out all of the following activities during the repair activities:


2. Carry out all the following activities when preparing for the repair activity: • check mouldings are correct and complete• identify the method of repair to be used• check availability of ancillary materials required

• select correct equipment for the activity• check equipment is suitable for use• identify what needs to be repaired

• identify and protect the moulding and repair materials in the work area3. Repair defects in six of the following types of composite mouldings:

• trim• closing panels• housings

• body panels• tubes• sections

• sandwich panels• structural• aerodynamic

• moulds• jigs

4. Repair defects in composite mouldings using four of the following methods: • localised curing• fettling• surface filling

• relieving distortion• separation of bonds• bonding

• resin injection• wet-lay patching• pre-preg patching

• core patching• insert/core potting• repair patches/kits

5. Repair defects using techniques/materials applicable to two of the following resins types: • polyester • epoxy • bismaleimide • cyanate ester • phenolic • vinyl ester

6. Repair defects using techniques/materials applicable to two of the following fibre types:• polyethylene • glass • aramid • carbon

7. Repair eight of the following types of defect in composite mouldings: • incomplete curing• dimensional• tolerances• surface finish• distortion

• blisters• bridging• de-lamination• broken fibres

• voids• dis-bonds• dents or ‘dings’• excessive adhesive

• damaged cores• wrong inserts• insert positions● impact damage

8. Repair a range of mouldings which comply with one of the following standards: • ISO 9000 Quality Assurance procedures• customer standards and requirements• company standards and procedures


419

Unit No 85: Repairing Composite Mouldings Knowledge statements:








specification etc.) and the completion of such documents8. Conventions and terminology used when repairing composite mouldings (eg, dis-bonds, de-lamination, resin

injection, resin voids, core potting, repair patches)9. Failure modes for various composite mouldings, and what can contribute to these10. Different types of composite resin systems, fibres, reinforcements, and their merits11. Different methods of production for composite mouldings, and their merits12. Different methods of trimming composite mouldings, and their merits13. Different methods of producing composite assemblies, and their merits14. Different bonding agents, methods used, and their merits15. Correct methods of storage and handling of composite materials16. Tools and equipment used for various activities associated with repairing composite mouldings17. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


420





required)evidence typedate carry out activities during repair activity (all)use correct issue production documentationuse relevant health and safety documentationuse correct tools/equipment/ ensure they are safe/suitably storedkeep the work area in safe conditioncarry out activities when preparing for repair activity (all)check mouldings are correct and completeidentify the method of repair to be usedcheck availability of ancillary material requiredidentify and protect moulding/ repair materials in work areaselect correct equipment for activitycheck equipment is suitable for useidentify what needs to be repairedrepair defects in types of composite mouldings (six)trimclosing panelshousingsbody panelstubessectionssandwich panelsstructuralaerodynamicmouldsjigsrepair defects in composite mouldings using methods (four)localised curingfettlingsurface fillingrelieving distortionseparation of bondsbondingresin injectionwet-lay patchingpre-peg patchingcore patchinginsert/core pottingrepair patches/kits


421





required)evidence typedate repair defects using techniques/materials applicable to resins types (two)polyesterepoxybismaleimidecyanate esterphenolicvinyl esterrepair defects using techniques/materials applicable to fibre types (two)polyethyleneglassaramidcarbonrepair types of defect in composite mouldings (eight)incomplete curingdimensionaltolerancessurface finishdistortionblistersbridgingde-laminationbroken fibresvoidsdis-bondsdents or ‘dings’excessive adhesivedamaged coreswrong insertsinsert positionsimpact damagerepair a range of mouldings which comply with standards (one)ISO 9000 Quality Assurance procedurescustomer standards and requirementscompany standards and procedures


Candidate: Date:

Assessor: Date:


422

Unit No 86: Applying Finishes to Composite Mouldings

Unit Summary

This unit identifies the competencies you need to apply finishes to composite mouldings (moulds, panels and components), in accordance with approved procedures. You will be required to use appropriate drawings, specifications and documentation to apply finishes, using the correct techniques.

You will apply finishes to composite mouldings using a range of techniques and processes. A variety of finishes will be applied to a range of resin and fibre materials.

Your responsibilities will require you to comply with organisational policy and procedures for the finishing activities undertaken, and to report any problems with the finishing activities, equipment or materials that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying finishing techniques and procedures to composite mouldings. You will understand the finishing techniques used, and their application, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the work output is to the required specification.

You will understand the safety precautions required when carrying out the finishing operations and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.


423

Unit No 86: Applying Finishes to Composite MouldingsPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Ensure the material surfaces to be treated are suitably prepared for the finishing operations to be carried outc. Check that the finishing equipment and treatment solutions are set up and maintained at satisfactory operating conditions and levelsd. Carry out the treatment process in accordance with operating procedures and the component specification requirementse. Ensure that the treated workpiece achieves the required characteristics and meets the finishing specificationf. Deal promptly and effectively with problems within your control and report those that cannot be solvedg. Dispose of waste and excess materials in line with agreed organisational proceduresh. Shut down the finishing equipment to a safe condition on completion of the processing activities


You must:1. Carry out all of the following during the finishing activities:

• use the correct issue production documentation (drawings, manuals, specifications, job cards)• use relevant health and safety documentation (material data sheets, COSHH sheets, risk assessments)• use the correct tools and equipment for the activity and ensure they are safe to use• keep the work area in a safe condition

2. Carry out all the following activities when preparing for the finishing activity: • check mouldings are correct and complete• check for any defects in the mouldings• check availability of ancillary materials required

• select correct equipment for the activity• check equipment is suitable for use• identify and protect the moulding in the work area

3. Apply finishes to composite mouldings using two of the following techniques: • cloth application • brush • spray • laying films • roller

4. Prepare surfaces of composite mouldings using two of the following methods: • abrading • bead blasting • water cleaning • solvent cleaning • priming

5. Apply two types of finishes to composite mouldings from: • surface sealers• primers

• top coats• adhesive films

• UV coatings• heatproof coatings

• speciality coatings• flexible coatings

6. Apply finishes to composite mouldings using three of the following: • one-part finishes• two-part finishes

• multiple coatings• combination coats

• solvent based• adhesive based

• water based • single coatings

7. Apply finishes to composite mouldings using four of the following consumable materials: • abrasives• masking tapes

• masking films• polishes

• thinners• solvents

• stoppers• fillers

• sealers• primers

• cutting compounds• cleaning agents

8. Apply finishes to composite mouldings suitable for two of the following resin types: • polyester • vinyl ester • epoxy • phenolic • bismaleimide • cyanate ester

9. Apply finishes to composite mouldings suitable for two of the following fibre types: • polyethylene • glass • aramid • carbon

10. Apply finishes to a range of mouldings which comply with one of the following standards:• ISO 9000 Quality Assurance procedures• customer standards and requirements• company standards and procedures


424

Unit No 86: Applying Finishes to Composite MouldingsKnowledge statements:






conventions to appropriate BS or ISO standards in relation to work undertaken 6. Quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting

specification etc.) and the completion of such documents7. Conventions and terminology used for applying finishes (eg, surface keying, finish thickness, matt finish, gloss finish,

treatment reactions)8. Different types of composite resin systems, fibres, reinforcements, and their merits9. Different finishes applied to composites, and their merits10. Correct methods of storage, handling and disposal of finishing materials11. Methods of preparation for applying different finishes12. Mixing ratios for two-part finishes, and the associated working times13. Methods of application for different finishes14. Problems that can occur during the finishing process, including defects such as contamination15. How defects can be overcome during the finishing activity16. Tools and equipment used in finishing activities, and their care, preparation and control procedures17. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


425





required)evidence typedate carry out during finishing activities (all)use correct issue production documentationuse relevant health and safety documentationuse correct tools/ equipment /ensure they are safe to usekeep work area in safe conditioncarry out activities when preparing for the finishing activity (all)check mouldings are correct and completecheck for any defects in the mouldingcheck availability of ancillary material requiredselect correct equipment for activitycheck equipment is suitable for useidentify and protect the moulding in the work areaapply finishes to composite mouldings using techniques (two)cloth applicationbrushspraylaying filmsrollerprepare surfaces of composite mouldings using methods (two)abradingbead blastingwater cleaningsolvent cleaningprimingapply types of finishes to composite moulding from (two)surface sealersprimerstop coatsadhesive filmsUV coatingsheatproof coatingsspeciality coatingsflexible coatingsapply finishes to composite mouldings using the following (three)one-part finishestwo-part finishesmultiple coatingscombination coats solvent basedadhesive basedwater basedsingle coatings



426


required)evidence typedate apply finishes to composite mouldings using consumable materials (four)abrasivesmasking tapesmasking filmspolishesthinnerssolventsstoppersfillerssealersprimerscutting compoundscleaning agentsapply finishes to composite mouldings suitable for resin types (two)polyester vinyl esterepoxyphenolicbismaleimidecyanate esterapply finishes to composite mouldings suitable for fibre types (two)polyethyleneglassaramidcarbonapply finishes to a range of mouldings which comply with standards (one)ISO quality assurance procedurescustomer standards and requirementscompany standards and procedures


Candidate: Date:

Assessor: Date:


427

Unit No 87: Trimming Composite Mouldings using Hand Tools

Unit Summary

This unit identifies the competencies you need to trim composite mouldings (moulds, components, splashes, jigs) using hand tools, in accordance with approved procedures. You will be required to use appropriate drawings, specifications and documentation to trim various mouldings, using the correct trimming techniques.

You will be expected to select the correct tools and equipment for the trimming activity. You will trim a range of composite mouldings incorporating a variety of features, and using cutting, sanding, drilling and polishing techniques and processes. Mouldings trimmed will include a range of resin and fibre materials.

Your responsibilities will require you to comply with organisational policy and procedures for the trimming activities undertaken, and to report any problems with the trimming activities, equipment or materials that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying composite moulding trimming techniques and procedures. You will understand the trimming techniques used, and their application, in adequate depth to provide a sound basis for carrying out the activities to the required specification.

You will understand the safety precautions required when carrying out the trimming activities and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.


428

Unit No 87: Trimming Composite Mouldings using Hand ToolsPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow relevant specifications for the component to be produced c. Obtain the appropriate tools and equipment for the shaping operations and check they are in a safe and usable conditiond. Shape the materials using appropriate methods and techniquese. Check that all the required shaping operations have been completed to the required specificationf. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must:1. Carry out all of the following activities during the trimming activities:


2. Carry out all the following activities when preparing for the trimming activity: • check moulding is correct and complete• check for any defects in the moulding• select correct equipment for the activity

• check equipment is suitable for use• identify and protect the moulding in the work area

3. Mark out mouldings using all of the following methods: • scriber • height gauge • moulded scribe lines • centre punch • trimming templates

4 Cut mouldings using two the following methods: • cutting wheels/discs • saws • routers • trim jigs

5. Sand mouldings using three of the following methods: • rubbing blocks • diamond files • pencil grinders • disc sanders • belt sanders

6. Use hand drill or pedestal drill to drill mouldings, using three of the following methods: • drill jigs • hole saws • counterbores • countersinks • drill bits

7. Polish mouldings using four of the following methods: • wet sanding• cutting compound

• polishing compound• rubbing block

• orbital sander • polisher

8. Trim mouldings using techniques for two of the following resins types: • polyester • vinyl ester • epoxy • phenolic • bismaleimide • cyanate ester

9. Trim mouldings using techniques for two of the following fibre types: • polyethylene • glass • aramid • carbon

10. Trim mouldings that require, or incorporate, eight of the following features: • straight edges• curved edges• flat surfaces• polished surfaces • shaped surfaces

• radius corners• returns• nett edges• joggle details• removal of join lines

• multiple holes• multiple hole sizes• countersinks• counterbores• further lay-up stages

• inserts to be drilled• inserts to be tapped• solid cores• honeycomb cores• edge filling

11. Trim a range of mouldings which comply with one of the following standards: • ISO 9000 Quality Assurance procedures• customer standards and requirements• company standards and procedures


429

Unit No 87: Trimming Composite Mouldings using Hand ToolsKnowledge statements:








specification etc.) and the completion of such documents8. Conventions and terminology used for trimming activities (eg, scribe lines, sanding grades, types of cutting tools,

speeds)9. Different types of manual and power tools, and their merits10. Different types of cutting tools and abrasives, and their merits11. Different types of materials used in cutting tools and abrasives, and their merits12. Different types of resins, fibres, reinforcement, and their merits13. The visual identification of cured composite materials14. The identification and rectification of defects in composite mouldings15. The methods used in the trimming of composite mouldings16. Operations and their sequence when preparing for trimming activities17. Methods for handling composite mouldings throughout the trimming activities18. Tools and equipment used trimming activities, and their care, preparation and control procedures19. The care and safe handling of composite mouldings throughout the trimming cycle20. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


430





required)evidence typedate carry out activities during trimming activities (all)use correct issue production documentationuse relevant health and safety documentationuse correct tools/equipment/ ensure they are safe to use/suitably storedkeep work area in safe conditioncarry out activities when preparing for the trimming activity (all)check mouldings are correct and completecheck for defects in mouldingselect correct equipment for activitycheck equipment is suitable for useidentify and protect the moulding in work areamark out mouldings using methods (all)scriberheight gaugemoulded scribe linescentre punchtrimming templatescut mouldings using methods (two)cutting wheels/discssaws routerstrim jigssand mouldings using methods (three)rubbing blocksdiamond filespencil grindersdisc sandersbelt sandersuse hand drill or pedestal drill to drill mouldings using methods (three)drill jigshole sawscounterborescountersinksdrill bitspolish mouldings using methods (four)wet sandingpolishing compoundorbital sanderpolishercutting compoundrubbing block



431


required)evidence typedate trim mouldings using techniques for resins types (two)polyestervinyl esterepoxyphenolicbismaleimidecyanate estertrim mouldings using techniques for fibre types (two)polyethylene glassaramidcarbontrim mouldings that require or incorporate features (eight)straight edgescurved edgesflat surfacespolished surfacesshaped surfacesradius cornersreturnsnett edgesjoggle detailsremoval of join linesmultiple holesmultiple hole sizescountersinkscounterboresfurther lay-up stagesinserts to be drilled inserts to be tapped solid coreshoneycomb coresedge filling


Candidate: Date:

Assessor: Date:


432

Unit No 88: Identifying Defects in Composite Mouldings

Unit Summary

This unit identifies the competencies you need to identify and deal with defects in composite mouldings (moulds, panels, components, jigs), in accordance with approved procedures. You will be required to use appropriate drawings, specifications and documentation to identify and deal with defects in composites mouldings.

You will be able to identify a range of defects in composite mouldings using various methods and techniques. Defects will be identified in a range of mouldings with a variety of resin and fibre materials.

Your responsibilities will require you to comply with organisational policy and procedures for the activities undertaken, and to report any problems with the activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to identifying defects in composite mouldings, and to making decisions on what action needs to be taken. You will understand composite materials, and their application, and will know about defects in adequate depth to provide a sound basis for dealing with the defects in line with organisation practice and procedures.

You will understand the safety precautions required when working with the composite mouldings and when using associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.


433

Unit No 88: Identifying Defects in Composite Mouldings Performance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Identify defects with regard to the product or asset specificationc. Assess the defects and determine action required to return the products and assets to specified condition d. Report recommendations for action to the appropriate people promptly and in accordance with organisational procedurese. Record details of defects in accordance with quality assurance and control systems and procedures


You must:1. Carry out all of the following during the inspection activities:


2. Identify defects in composite mouldings using four of the following methods: • touch• sound

• visual• measurement

• mechanical tests• CMM

• NDT• stage inspection

3. Identify defects in six of the following types of composite mouldings: • trim• closing panels• housings

• body panels• tubes• sections

• sandwich panels• structural• aerodynamic

• moulds• jigs

4. Identify defects applicable to two of the following resin types: • polyester • vinyl ester • epoxy • phenolic • bismaleimide • cyanate ester

5. Identify defects applicable to two of the following fibre types: • polyethylene • glass • aramid • carbon

6. Identify eight of the following types of defect in composite mouldings: • incomplete curing• dimensional• tolerances• ply orientation• wrong join type• surface finish

• distortion• blisters• bridging• de-lamination• wrinkles• broken fibres

• splintering• voids• dents or ‘dings’• dis-bonds• resin rich areas• incorrect material

• excessive adhesive• damaged cores• wrong inserts• insert positions● impact damage

7. Ensure actions recommended to rectify the defect comply with one of the following standards: • ISO 9000 Quality Assurance procedures• customer standards and requirements• company standards and procedures


434

Unit No 88: Identifying Defects in Composite Mouldings Knowledge statements:








specification etc.) and the completion of such documents8. Conventions and terminology used when identifying and rectifying defects (eg, dis-bonds, de-lamination, resin

injection, resin voids, core potting, repair patches)9. Failure modes for various composite mouldings, and what can contribute to these10. Different types of composite resin systems, fibres, reinforcements, and their merits11. Different methods of production for composite mouldings, and their merits12. Different methods of trimming composite mouldings, and their merits13. Different methods of producing composite assemblies, and their merits14. Different bonding agents, methods used, and their merits15. Correct methods of storage and handling of composite materials16. Tools and equipment used for various activities associated with composite mouldings17. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


435





required)evidence typedate carry out activities during inspection activities (all)use correct issue production documentationuse relevant health and safety documentationuse correct tools and equipment/ensure they are safe to use/suitably storedkeep work area in safe conditionidentify defects in composite mouldings using methods (four)touchsound visualmeasurementmechanical testsCMMNDTstage inspectionidentify defects in types of composite mouldings (six)trimclosing panelshousingsbody panelstubessectionssandwich panelsstructuralaerodynamicmouldsjigsidentify defects applicable to resin types (two)polyestervinyl esterepoxyphenolicbismaleimidecyanate esteridentify defects applicable to fibre types (two)polyethyleneglassaramidcarbon


436





required)evidence typedate identify types of defect in composite mouldings (eight)incomplete curingdimensionaltolerancesply orientationwrong join typesurface finishdistortionblistersbridgingde-laminationwrinklesbroken fibressplinteringvoidsdents or ‘dings’dis-bondsresin rich areasincorrect materialexcessive adhesive damaged coreswrong insertsinsert positionsimpact damageensure actions recommended to rectify the defect comply with standards (one)ISO 9000 Quality Assurance procedurescustomer standards and requirementscompany standards and procedures


Candidate: Date:

Assessor: Date:


437

Unit No 89: Inspecting Optical Components

Unit Summary

This unit identifies the competencies you need to carry out optical inspection operations, in accordance with approved procedures, using optical inspection techniques and equipment. You will be required to check components made from a range of optical materials, using a mixture of inspection equipment, as appropriate. You will be expected to inspect a range of components that combine a number of different features, such as centre-thickness, diameters, generated blanks, optical lens form and power, angles, profiles, and with cosmetic defects.

You will be required to operate the equipment in line with safe working practices and approved procedures, and to continuously monitor the equipment operations, making any necessary adjustments in order to ensure that the work output is to the required quality and accuracy. Meeting production targets will be an important issue, and your production records must show consistent and satisfactory performance.

Your responsibilities will require you to comply with organisational policy and procedures for the optical inspection activities undertaken, and to report any problems with the optical inspection activities, equipment or materials that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying optical inspection procedures. You will understand the optical inspection procedures used, and their application, and be familiar with the equipment, materials and consumables, in adequate depth to provide a sound basis for carrying out the activities, identifying out-of-specification components, and ensuring accepted components meet the required specification.

You will understand the safety precautions required when working with the inspection equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.


438

Unit No 89: Inspecting Optical ComponentsPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the correct specification for the product or equipment being inspectedc. Use the correct equipment to carry out the inspectiond. Identify and confirm the inspection checks to be made and acceptance criteria to be usede. Carry out all required inspections as specifiedf. Identify any defects or variations from the specificationg. Record the results of the inspection in the appropriate formath. Deal promptly and effectively with problems within your control and report those that cannot be solved

Scope of the unit:The numbers of scope items specified (below) indicate the minimum requirements for this Occupational Standard.You must:1. Carry out all the following activities during the inspection activity:

obtain relevant and current documentation for the components being inspectedcheck that the required inspection equipment is within current calibration datesuse appropriate inspection techniques to check the componentsdetermine any out-of-specification components complete all relevant inspection documentation, accurately and legiblyapply safe working practices at all times

2. Operate six types of optical inspection equipment from the following: lens centring rigcentre thickness gaugemicroscopesmicrometers

optical measuring equipmentfocometer test equipmentauto collimators optical spheres

optical flatsdial test indicatorsslip gaugesvernier equipment

interferometry and phase analysis equipment shadowgraph test equipment3. Inspect five optical components from the following:

infra-red lens combiners infra-red glass flats infra-red glass domescylinders glass prisms infra-red prisms plastic lens componentsglass lens optical mirrors profiled optical components

4. Inspect ten features of machined optical components from the following:prism anglesconcentricityprofilesfocal lengthflats power error

lens diameterlens form errorsag depthlens centringcosmetic defect

cap heightflats form errorcentre thicknessrefractive indexother features

truncationlens wedgeflat/parallelismlens power (radius)

5. Use inspection methods and techniques suitable for components made from six different types of materials:germaniumbarium crowns

dense flintsflints/light flints

infra-red glass 4,5,6barium dense flints

zinc selenidezinc sulphide

• silicon • plastics

lanthanum crownsanomalous dispersion flour crownsoptical neutral density glass

optical orange filter glassoptical blue filter glassother

thallium ideobromideborosilicate crowns

6. Inspect components within all of the following quality and accuracy standards, as applicable:• BS 4301:1991 Optical elements and systems • ISO 10110 Optical elements and systems

DIN 3140:1978 Pt1-10 Preparation of optical elements and drawingsMIL-O-13830:1963 General specification governing the manufacture and inspection of optical componentsBS 6001 Pt1:1991 Sampling procedures for optical inspection


439

Unit No 89: Inspecting Optical ComponentsKnowledge statements:


1. The safe working practices and procedures to be followed while using inspection equipment2. The safety mechanisms on the equipment, and the procedure for checking that they function correctly3. The personal protective equipment that needs to be worn, and where this can be obtained4. The hazards associated with optical inspection operations, and how they can be minimised5. The importance of keeping the work area clean and tidy6. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing8. The methods of calculating data from engineering drawings/specifications9. The various optical inspection operations to be performed, and types of equipment used10. How to calibrate equipment before inspection operations are carried out11. How to recognise the various cosmetic defects12. How to handle and store all inspection equipment, safely and correctly13. How tool wear affects surface finish and dimensional accuracy14. How the various types of materials will affect the way the operation is performed15. The effect of clamping the workpiece, and how this can cause distortion in the finished component16. How to recognise inspection equipment faults, and identify when inspection equipment needs refurbishment 17. The problems that can occur with optical inspection activities, and how they can be overcome18. The quality control procedures used, inspection checks that need to be carried out, and the equipment used19. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


440





required)evidence typedate carry out activities during inspection activity (all)obtain relevant/current documentation for components being testedcheck inspection equipment is within current calibration datesuse appropriate inspection techniques to check componentsdetermine any out-of-specification componentscomplete all relevant inspection documentation, accurately/legiblyapply safe working practicesoperate types of optical inspection equipment from the following (six)lens centring rigcentre thickness gaugemicroscopesmicrometersinterferometry and phase analysis equipmentoptical measuring equipmentfocometer test equipmentauto collimatorsoptical spheresoptical flatsdial test indicatorsslip gaugesvernier equipment shadowgraph test equipmentinspect optical components (five)infra-red lenscylindersglass lenscombinersglass prismsoptical mirrorsinfra-red glass flatsinfra-red prismsprofiled optical componentsinfra-red glass domesplastic lens components


441





required)evidence typedate inspect features of machined optical components (ten)prism anglesconcentricityprofilesfocal lengthflats power errorlens diameterlens form errorsag depthlens centringcosmetic defectcap heightflats from errorcentre thicknessrefractive indexother featurestruncationlens wedgeflat/parallelismlens power (radius)use inspection methods/techniques made from different types of material (six)germaniumbarium crownslanthanum crownsanomalous dispersion flour crownoptical neutral density glassdense flintsflints/light flintsinfra-red glass 4,5,6barium dense flintsoptical orange filter glassoptical blue filter glassotherzinc selenidezinc sulphidesiliconplasticsthallium ideobromideborosilicate crowns


442





required)evidence typedate inspect components within quality and accuracy standards (all)BS 4301:1991 optical elements and systemsDIN 3140:1978 preparation of optical elements/drawingsMIL-O-13830:1963 general specification governing the manufacturer/inspection of optical componentssampling procedures for optical inspection


Candidate: Date:

Assessor: Date:


443

Unit No 90: Machining Infra-Red/Special Material Lenses

Unit Summary

This unit identifies the competencies you need to carry out machining operations on optical infra-red and special materials, in accordance with approved procedures, using optical infra-red process machines. You will be required to set up and operate a range of machines, in order to produce the components that combine a mixture of processes identified for infra-red and special materials, using a selection of specified optical lens and flat materials. You will be expected to produce a range of components that combine a number of different features, such as centre thickness, diameters, generated blanks, optical lens form and power.

You will be required to set up and operate the machine in line with safe working practices and approved procedures, and to continuously monitor the machining operations, making any necessary adjustments in order to ensure that the work output is to the required quality and accuracy. Meeting production targets will be an important issue, and your production records must show consistent and satisfactory performance.

Your responsibilities will require you to comply with organisational policy and procedures for the optical machining activities undertaken, and to report any problems with the optical machining activities, materials or equipment that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying optical machining procedures. You will understand the optical lens, and flat infra-red and special materials processes used, and their application, and will know about the setting-up procedures, equipment, materials and consumables, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the work output is to the required specification.



444

Unit No 90: Machining Infra-Red/Special Material LensesPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Confirm that the machine is set up and ready for the machining activities to be carried out c. Manipulate the machine tool controls safely and correctly in line with operational procedures d. Produce components to the required quality and within the specified dimensional accuracye. Carry out quality sampling checks at suitable intervals f. Deal promptly and effectively with problems within your control and report those that cannot be solvedg. Shut down the equipment to a safe condition on conclusion of the machining activities.


You must: 1. Ensure that you apply all the following checks and practices during the machining activities:

• ensure appropriate machine guards are in place and correctly adjusted• hold the components securely without damage or distortion• ensure tooling is appropriate for the operations and is maintained in a suitable condition• set the tooling and machine operating parameters to achieve the component specification• adjust machine settings as required during the machining activities to maintain component accuracyapply safe working practices at all times

2. Operate three types of optical lens process machines from the following:conventional pitch lens silk polishing flat silk polishingspecial materials automated generatinglens edging

3. Produce machined optical components that combine different operations and cover six of the following:centre thicknesslens diameterlens concentricity

flat parallelismlens form analysislens power analysis

lens surface generationlens cosmetic defectslens truncation and cap height

4. Machine four different types of materials from the following:zinc selenidezinc sulphideoptical siliconother optical grade

optical infra-red glass 4optical infra-red glass 5optical infra-red glass 6other appropriate material

optical cleartranoptical grade germaniumoptical thallium ideobromide

5. Produce components with dimensional accuracy, form and surface quality to one of the following standards:BS 4301:1991 Optical elements and systems ISO 10110 Optical elements and systemsDIN 3140:1978 Pt1-10 Preparation of optical elements and drawingsMIL-O-13830:1963 General specification governing manufacture and inspection of optical componentsBS 6001 : Pt1 .1991 Sampling procedures for optical inspection

6. Carry out the necessary checks for accuracy during production of a least five of the following:optical bevels lens chamfers lens diameters lens surface finishlens cap height optical parallelism optical truncationslens centre thickness lens surface form error lens surface power error


445

Unit No 90: Machining Infra-Red/Special Material LensesKnowledge statements:


1. The safe working practices and procedures that need to be followed while operating optical lens generating, smoothing and polishing equipment

2. The safety mechanisms on the machine, and the procedure for checking that they function correctly3. Operation of the machine controls in both set-up and run modes, and how to stop the machine in an emergency4. The personal protective equipment that needs to be worn, and where this can be obtained5. The hazards associated with optical lens process operations, and how they can be minimised6. The importance of keeping the work area clean and tidy7. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing9. The various optical lens operations that can be performed, and the shapes and types of tooling that can be used (fly

cutters, diamond abrasive wheels, polyurethane polishers, pitch polishers and silk polishers)10. The methods that can be used to set up the workpiece prior to the operation, to minimise optical wedge and

parallelism in relation to the cutting tool11. The effect of backlash in machine slides, dials and screws, and how this can be overcome12. How to handle and store all cutting tools and kit required, safe and correctly13. Factors which affect the selection of cutting feeds, pressures and speeds required, and the depth of cut that can be

taken (workpiece rigidity, machine condition, types of tooling, material, finish and tolerance required)14. How tool wear affects surface finish and dimensional accuracy15. How the various types of materials will affect the way the operation is performed16. The application of cutting fluids with regard to the range of material being produced17. The effect of clamping the workpiece, and how this can cause distortion in the finished component18. How to recognise machine faults and identify when tooling needs refurbishment19. The problems that can occur with optical lens infra-red and special material machining activities, and how they can

be overcome20. The quality control procedures used, inspection checks that need to be carried out, and the equipment used21. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


446





required)evidence typedate apply checks and practices during machining activities (all)ensure appropriate machine guards are in place/correctly adjustedhold components securely without damage/distortionensure tooling is appropriate for operations/maintained in a suitable conditionset the tooling and machine operating parameters to achieve the component specificationadjust machine settings as required during machining activities to maintain component accuracyapply safe working practicesoperate types of optical lens process machines (three)conventional pitchspecial materialslens edginglens silk polishingautomatedflat silk polishinggeneratingproduce machined optical components that combine different operations (six)centre thicknesslens diameterlens concentricityflat parallelismlens from analysislens power analysislens surface generationlens cosmetic defectslens truncation and cap heightmachine different types of material from the following (four)zinc selenidezinc sulphideoptical siliconother optical gradeoptical infra-red glass 4optical infra-red glass 5 optical infra-red glass 6other appropriate materialoptical cleartranoptical grade germaniumoptical thallium ideobromide


447





required)evidence typedate produce components with dimensional accuracy, form and surface quality to standards (one)BS 4301:1991 optical elements and systemsISO 10110 optical elements and systemsDIN 3140:1978 Pt1-10 preparation of optical elements and drawingsMIL-O-13830:1963 general specification governing manufacture/inspection of optical componentsBS 6001: Pt1.1991 sampling procedures for optical inspectioncarry out necessary checks for accuracy during production (five)optical bevelslens cap heightlens centre thicknesslens chamfersoptical parallelismlens surface form errorlens diameteroptical truncationslens surface power errorlens surface finish


Candidate: Date:

Assessor: Date:


448

Unit No 91: Machining Optical Glass Lenses

Unit Summary

This unit identifies the competencies you need to carry out machining operations on optical lens glass material, in accordance with approved procedures, using optical lens glass process machines. You will be required to set up and operate a range of machines, in order to produce components that combine a mixture of processes identified for optical lens glass machining, using a selection of specified optical lens glass materials. You will be expected to produce a range of components that combine a number of different features such as centre thickness, diameters, generated blanks, optical lens form and power.

You will be required to set up and operate the machines in line with safe working practices and approved procedures, and to continuously monitor the machining operations, making any necessary adjustments in order to ensure that the work output is to the required quality and accuracy. Meeting production targets will be an important issue, and your production records must show consistent and satisfactory performance.

Your responsibilities will require you to comply with organisational policy and procedures for the optical machining activities undertaken, and to report any problems with the optical machining activities, materials or equipment that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying optical machining procedures. You will understand the optical lens glass processes used, and their application, and will know about the equipment, materials and consumables, in adequate depth to provide a sound basis for setting-up the machines, carrying out the activities, correcting faults, and ensuring the work output is to the required specification.



449

Unit No 91: Machining Optical Glass LensesPerformance statements:



You must:1 . Carry out all the following activities during the setting up and machining activities:

• ensure appropriate machine guards are in place and correctly adjusted • hold the components securely without damage or distortion• ensure tooling is appropriate for the operations and is maintained in a suitable condition• set the tooling and machine operating parameters to achieve the component specification• adjust machine settings as required during the machining activities to maintain component accuracyapply safe working practices at all times

2. Set up and operate three types of optical lens process machines from the following:lens edging automated small lens conventional large lens pitch generating automated large lens conventional small lens pitch

3. Produce optical machined components which combine different operations and cover six of the following:centre thicknesslens diameterlens concentricity

lens wedgelens form analysislens power analysis

lens surface generationlens cosmetic defectslens truncation and cap height

4. Machine four different types of materials from the following:barium crowns borosilicate crownsflints/light flints optical orange filter glass

optical blue filter glassoptical neutral density glassanomalous dispersion flour crownsother optical grades

dense flintsbarium dense flintslanthanum crowns

5. Produce components with dimensional accuracy, form and surface quality to one of the following standards:BS 4301:1991: Optical elements and systems ISO 10110 Optical elements and systemsDIN 3140:1978 Pt 1-10 Preparation of optical elements and drawingsMIL-O-13830:1963 General specification governing manufacture and inspection of optical componentsBS 6001:1991 Pt1 Sampling procedures for optical inspection

6. Carry out the necessary checks for accuracy during production of five of the following:optical bevelsoptical lens wedgeoptical parallelism

optical truncationslens cap heightlens chamfers

lens diameterslens surface finishlens surface power error

lens centre thickness lens surface form error


450

Unit No 91: Machining Optical Glass LensesKnowledge statements:


1. The safe working practices and procedures that need to be followed while operating optical lens, generating, smoothing and polishing equipment

2. The safety mechanisms on the machine, and the procedure for checking that they function correctly3. The operation of the machine controls in both set-up and run modes, and how to stop the machine in an

emergency4. The personal protective equipment that needs to be worn, and where this can be obtained5. The hazards associated with optical lens process operations, and how they can be minimised6. The importance of keeping the work area clean and tidy 7. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing9. The various optical lens operations that can be performed, and the shapes and types of tooling that can be used

(diamond abrasive wheels, diamond pellet smoothers, polyurethane polishers and pitch polishers)10. The methods that can be used to set up the workpiece prior to the operation, to minimise optical wedge and

parallelism in relation to the cutting tool11. The effect of backlash in machines slides, dials and screws, and how this can be overcome12. How to handle and store all cutting tools and kit required, safe and correctly13. Factors which affect the selection of cutting feeds, pressures and speeds required, and the depth of cut that can be

taken (workpiece rigidity, machine condition, types of tooling, material, finish and tolerance required)14. How tool wear affects surface finish and dimensional accuracy15. How the various types of materials will affect the way the operation is performed16. The application of cutting fluids/rouges, with regard to the range of material being produced17. The effect of clamping the workpiece, and how this can cause distortion in the finished component18. How to recognise machine faults and identify when tooling needs refurbishment19. The problems that can occur with optical lens glass machining activities, and how they can be overcome20. The quality controls procedures used, inspection checks that need to be carried out, and the equipment used21. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


451





required)evidence typedate carry out activities during the setting up and machining activities (all)ensure appropriate machine guards are in place/correctly adjustedhold the components securely without damage/distortionensure tooling is appropriate for operations/maintained in a suitable conditionset tooling/machine operating parameters to achieve the component specificationsadjust machine settings as required during machining activitiesapply safe working practicesset up and operate optical lens process machines (three)lens edginggeneratingautomated small lensautomated large lensconventional large lens pitch conventional small lens pitchproduce optical machined components which combine different operations and cover (six)centre thicknesslens diameterlens concentricitylens wedgelens form analysislens power analysislens surface generationlens cosmetic defectslens truncation and cap heightmachine different types of material from the following (four)barium crownsborosilicate crownsflints/light flintsoptical orange filter glassoptical blue filter glassoptical neutral density glassanomalous dispersion flour crownsother optical gradesdense flintsbarium dense flintslanthanum crowns


452





required)evidence typedate produce components with dimensional accuracy, form and surface quality to standards (one)BS 4301:1991: optical elements and systemsDIN 3140:1978 Pt1-10 preparation of optical elements and drawingsMIL-O-13830:1963 general specification governing manufacture/inspection of optical componentsISO 10110 optical elements and systemsBS 6001:1991 Pt1 sampling procedures for optical inspectionnecessary checks for accuracy during production (five)optical bevelsoptical lens wedgeoptical parallelismlens centre thicknessoptical truncationslens cap heightlens chamferslens surface form errorlens diameterslens surface finishlens surface power error


Candidate: Date:

Assessor: Date:


453

Unit No 92: Machining Optical Prism and Flat Components

Unit Summary

This unit identifies the competencies you need to carry out machining operations on optical prisms and flat components, in accordance with approved procedures, using a range of optical prism and flat process machines. You will be required to set up the machine for the operations to be performed, and to check that all the required components or materials and consumables are available. In operating the machine, you will be expected to produce a range of components that combine a number of different features such as angles, flats, parallelism, wedge shapes, chamfers and bevels, using a selection of specified optical prism and flat materials. You will also be required to check finished components that have been machined by the combination of a mixture of processes, for accuracy and quality.

You will be required to set up and operate the machine in line with safe working practices and approved procedures and to continuously monitor the machining operations, making any necessary adjustments to settings in order to ensure that the work output is to the required quality and accuracy. Meeting production targets will be an important issue, and your production records must show consistent and satisfactory performance.

Your responsibilities will require you to comply with organisational policy and procedures for the optical machining activities undertaken, and to report any problems with the optical machining activities, materials, tooling or consumables that you cannot personally resolve, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying optical machining procedures. You will understand the optical prism and flat machining processes, and their application, and will know about the equipment, materials and consumables, in adequate depth to provide a sound basis for carrying out the activities to the required specification.



454

Unit No 92: Machining Optical Prism and Flat ComponentsPerformance statements:



You must:1. Ensure that you apply all the following checks and practices during the setting up and machining activities:

ensure appropriate machine guards are in place and correctly adjustedhold the components securely without damage or distortionensure tooling is appropriate for the operations and is maintained in a suitable conditionset the tooling and machine operating parameters to achieve component specificationuse appropriate machining techniquesadjust machine settings as required to maintain component accuracy apply safe working practices at all times

2. Operate four of the following types of optical prism and flat process machines:preparation and smoothing twin lap flat polishing lap-master flat and prismhard lap flat and prism

polishingroof prism process (accurate angles)

3. Produce machined optical components which combine different operations and cover six of the following.flat centre thickness angular tolerances flatness tolerancesparallelism tolerances cosmetic tolerances transmission tolerancesfinished size tolerances prism chamfers/bevels tolerances

4. Machine four different types of materials from the following: optical grade germanium zinc selenide prisms and flats zinc sulphide prisms and flatsborosilicate crowns barium crowns dense flintsoptical orange filter glassoptical blue filter glass

optical neutral density glassflint/light flints

barium dense flintslanthanum crowns

anomalous dispersion flour crowns other appropriate optical material5. Produce components with dimensional accuracy, form and surface quality to one of the following standards:

BS 4301:1991: Optical elements and systems ISO 10110 Optical elements and systemsDIN 3140:1978 Pt1-10 Preparation of optical elements and drawingsMIL-O-13830:1963 General specification governing manufacture and inspection of optical componentsBS 6001: Pt1 .1991: Sampling procedures for optical inspection

6. Carry out the necessary checks for optical accuracy during production of five of the following:flatness prism chamfers and bevels transmission deviation measurementflat centre thickness prism surface cosmetics prism flatness measurementflat surface cosmetics flat chamfers and bevels prism angular measurementflat parallelism prism balk height measurement flatness transmission


455

Unit No 92: Machining Optical Prism and Flat ComponentsKnowledge statements:


1. The safe working practices and procedures that need to be followed while operating optical prism preparation, smoothing and polishing equipment

2. The safety mechanisms on the machines, and the procedure for checking that they function correctly3. The operation of the machine controls in both set-up and run modes, and how to stop the machine in an

emergency4. The personal protective equipment that needs to be worn, and where this can be obtained5. The hazards associated with optical prism process operations, and how they can be minimised6. The importance of keeping the work area clean and tidy7. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing9. The various optical prism operations that can be performed, and the shapes and types of tooling that can be used

(polyurethane polishers, pitch lap polisher)10. The methods that can be used to set up the workpiece prior to the operation, to minimise optical wedge and

parallelism in relation to the cutting tool (alloy jigs, plaster blocks, pitch pads)11. How to handle and store all tools and kit required, safely and correctly12. Factors which affect the selection of cutting feeds pressures and speeds required (types of tooling used, material

used, finish and tolerance required)13. How tool wear affects surface finish and dimensional accuracy14. How the various types of materials will affect the way the operation is performed15. The application of cutting fluids with regard to the range of material being produced16. The effect of clamping the workpiece, and how this can cause distortion in the finished component 17. The problems that can occur with optical prism machining activities, and how they can be overcome18. The quality controls procedures used, inspection checks that need to be carried out, and the equipment used to

achieve required component19. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


456





required)evidence typedate apply checks and practices during the setting up and machining activities (all)ensure appropriate machine guards are in place/correctly adjustedhold components securely without damage/distortionensure tooling is appropriate/maintained in suitable conditionset tooling/machine operating parameters to achieve component specificationuse appropriate machining techniquesadjust machine settings to maintain component accuracy apply safe working practicesoperate types of optical prism and flat process machines (four)preparation and smoothinghard lap flat/prism polishingtwin lap flat polishingroof prism processlap master flat and prismproduce machined optical components which combine different operations and cover (six)flat centre thicknessparallelism tolerancesfinished size tolerancesangular tolerances cosmetic tolerancesprism chamfers/bevels tolerancesflatness tolerancestransmission tolerancesmachine types of material (four)optical grade germaniumborosilicate crowns optical orange filter glassoptical blue filter glass anomalous dispersion flour crownszinc selenide prisms and flatsbarium crownsoptical neutral density glassflint/light flintsother appropriate optical materialzinc sulphide prisms and flatsdense flintsbarium dense flintslanthanum crowns


457





required)evidence typedate produce components with dimensional accuracy, form and surface quality to standards (one)BS 4301:1991: optical elements and systemsISO 10110 optical elements and systemsDIN 3140:1978 Pt 1-10 preparation of optical elements and drawingsMIL-O-13830:1963 general specification governing manufacture and inspection of optical componentsBS 6001: Pt 1 1991: sampling procedures for optical inspectioncarry out necessary checks for optical accuracy during production (five)flatnessflat centre thicknessflat surface cosmeticsflat parallelismprism chamfers and bevelsprism surface cosmeticsflat chamfers and bevelsprism balk height measurementtransmission deviation measurementprism flatness measurementprism angular measurementflatness transmission


Candidate: Date:

Assessor: Date:


458

Unit No 93: Setting CNC Aspheric Glass and Diamond Turning Machines

Unit Summary

This unit identifies the competencies you need to set up Computer Numerical Controlled (CNC) machines or CNC machining centres for the machining of aspheric glass and diamond turned components, in accordance with approved procedures. You will be expected to select the appropriate workholding devices, and to mount and secure them to the machine spindle. You will also be required to select the appropriate cutting tools, to mount and secure them to the appropriate tool holding devices, and to place the cutting tools in the relevant positions within the tool posts, turrets, slides or tool change magazine/carousel, where this is applicable.

You will need to ensure that all the tools have been allocated a relevant tool number, and that the relevant data on their co-ordinates and datum positions are entered into the operating program and machine. You will also be required to produce tool path information for each setup, and edit where required. This will involve loading and proving component programs, checking for errors/faults, editing and saving program changes. You must produce trial components and prove the machine is working satisfactorily before declaring the machine ready for production. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.


Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting-up procedures used. You will understand the CNC turning machine used, and its application, and will know about the workholding devices, tooling, machine operating programs and setting-up procedures, in adequate depth to provide a sound basis for setting up the equipment, correcting faults and ensuring the work output is produced to the required specification.



459

Unit No 93: Setting CNC Aspheric Glass and Diamond Turning MachinesPerformance statements:




• confirm the correct operating programme has been loaded• check the tooling is in a usable condition and appropriate to the operations being performed• ensure the workpiece is correctly positioned and secured without distortion• update programme tool data as applicable• position and adjust machine guards• apply safe working practices

2. Prepare two of the following types of optical CNC machines in readiness for production:aspheric generating aspheric polishing diamond turning aspheric process diamond turning diffractive/hybrid process

3. Position and secure workpieces using two of the following workholding methods and devices: chucks faceplates. other workholding devices

4. Select and mount, in the appropriate tool holding device, three of the following types of cutting tool: form toolsroughing toolsfinishing tools

half radius toolsedging/step tools

5. Prepare the tooling for operation by carrying out all of the following activities, as applicable to the machine type: mounting tools in the correct position in the tool posts, turrets, magazine or carousel checking tools have a specific tool number in relation to the operating programentering all relevant tool data to the operating program (tool lengths, tool offsets, radius compensation)presetting tooling using setting jigs/fixturessetting tool datumsaving changes to programme

5. Make trial components to prove the machine is operating to required specification, to include all the following: BS 4301:1991: Optical elements and systemsISO 10110: Optical elements and systemsDIN 3140:1978 Pt1-10 Preparation of optical elements and drawingsMIL-O-13830:1963 General specification governing manufacture and inspection of optical componentsBS 6001: Pt1 1991 : Sampling procedures for optical inspection


460

Unit No 93: Setting CNC Aspheric Glass and Diamond Turning MachinesKnowledge statements:


1. The specific safety precautions to be taken when setting up workholding devices and tooling on CNC machines2. How to start and stop the machine in normal and emergency situations3. The importance of wearing the appropriate protective clothing and equipment, and of keeping the work area clean and

tidy4. The hazards associated with working on CNC machines (such as use of power operated chucks, moving machinery,

automatic machine operation, lifting and handling workholding devices, and airborne particles), and how to minimise them

5. How to handle and store cutting tools, and how to verify programs are safe and correct6. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing8. The relationship between design and manufacture of aspheric components9. The range of workholding methods and devices that are used on CNC machines10. Why it is important to set the workholding device in relation to the machine datums and reference points11. The methods of setting the workholding devices, and the tools and equipment that can be used12. The range of cutting tools that are used on CNC lathes for aspheric glass and diamond turning operations, and typical

applications13. How to check that the cutting tools are in a safe and serviceable condition14. The various tool holding devices that are used, and the methods of correctly mounting and securing the cutting tools to

the tool holders15. How to place the machine into the correct operating mode, and how to access the program edit facility in order to

enter tooling data (such as tool datums, positions, lengths, offsets and radius compensation)16. How to conduct trial runs, using single block run, dry run and feed/speed override controls17. The settings that you need to check before allowing the machine to operate in full program run mode18. How the various types of materials will affect the feeds and speeds that can be used19. The application of cutting fluids20. Typical problems that can occur with the setting up of the tooling and workholding devices, and what to do if they



461





required)evidence typedate activities during setting up (all)correct operating programmecheck the tooling is in usable conditionworkpiece is correctly positionedupdate programme tool dataadjust machine guardssafe working practicesprepare CNC machines in readiness for production (two)aspheric generatingaspheric polishingdiamond turning aspheric processdiamond turning diffractive/hybrid processposition and secure workpieces (two)chucksfaceplatesother workholding devicesappropriate tool holding devices (three)form toolsroughing toolsfinishing toolshalf radius toolsedging/step toolsprepare the tooling for operation (all)mounting tools in the correct positionchecking tools have a specific numberrelevant tool datapresetting tooling setting tool datum saving changes to programmeproduce components with dimensional accuracy (one)optical elements and systemsoptical elements and systemsoptical elements and drawingsinspection of optical componentsprocedures for optical inspection


Candidate: Date:

Assessor: Date:


462

Unit No 94: Machining Components using CNC Aspheric Glass and Diamond Turning Machines

Unit Summary

This unit identifies the competencies you need to carry out the machining of aspheric glass and diamond turned components, using Computer Numerical Controlled (CNC) machines or CNC machining centres, in accordance with approved procedures. You will be required to produce a range of aspheric components of various infra-red and visible materials, which combine a range of different features, such as aspheric form, power, surface roughness, cap height, etc. You will also be required to check and verify finished components, using a variety of metrology equipment, to ensure they meet the required specifications.


Your responsibilities will require you to comply with organisational policy and procedures for the optical machining activities undertaken, and to report any problems with the optical machining activities, materials or equipment used that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying optical machining procedures. You will understand the aspheric glass and diamond turning processes used, and their application, and will know about the equipment, materials and consumables, in adequate depth to provide a sound basis for carrying out the activities to the required specification.



463





You must:1. Ensure that you apply all the following checks and practices during the machining activities:

• machine guards are in place and correctly adjusted• components are correctly positioned and held securely without distortion• cutting tools are in a suitable condition● the operating program is at the correct start point ● the workpiece is clear of the machine spindle● safe working practices and startup procedures are observed● machine settings are adjusted as required to maintain accuracy

2. Operate three of the following aspheric lens processes:glass aspheric generating processglass aspheric polishing process

diamond turning aspheric processdiamond turning diffractive/hybrid process

3. Produce machined optical components that combine different operations and cover six of the following:centre thicknesslens cosmetic defectslens concentricity

lens cap heightlens diameter/step feature, anglelens aspheric form analysis

lens surface roughnesslens power analysis/radiuslens diffractive step height

4. Machine five different types of materials from the following:zinc selenide zinc sulphide optical silicon optical cleartranoptical infra-red glass 4 optical infra-red glass 5 optical infra-red glass 6gallium arsenide acrylic optical glass optical grade germaniumoptical thallium ideobromide aluminium other appropriate optical material

5. Produce components with dimensional accuracy, form and surface quality to one of the following standards as applicable to the operations:

BS 4301:1991: Optical elements and systemsISO 10110 Optical elements and systemsDIN 3140:1978 Pt1-10 Preparation of optical elements and drawingsMIL-O-13830:1963 General specification governing manufacture and inspection of optical componentsBS 6001 : Pt1:1991 : Sampling procedures for optical inspection

6. Carry out the necessary checks for accuracy during production of all of the following:lens chamferslens surface finish

lens diameterlens cap height

lens centre thicknesslens power error

lens surface power error


464




1. The safe working practices and procedures that need to be followed while operating CNC aspheric lens generating, and polishing equipment and diamond turning equipment


emergency4. The personal protective equipment that needs to be worn, and where this can be obtained5. The hazards associated with aspheric lens process operations, and how they can be minimised6. The importance of keeping the work area clean and tidy7. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing9. The relationship between the design and manufacture of aspheric components10. The process methods of aspheric manufacture, and the use of a variety of tools (including diamond tip tools,

diamond abrasive wheels and polishing tools)11. The lens mounting methods used to set up the work-piece prior to operation, to minimise wedge error,

concentricity and astigmatism12. The effect of backlash in machines slides, dials and screws, and how this can be overcome13. How to handle and store all cutting tools and kit required, safe and correctly14. Factors which affect the selection of cutting feeds, pressures and speeds required, and the depth of cut that can be

taken (workpiece rigidity, machine condition, types of tooling, material, finish and tolerance required)15. How tool wear affects surface finish and dimensional accuracy16. How the various types of materials will affect the way the operation is performed17. The application of cutting fluids with regard to the range of material being produced18. How to recognise machine faults and identify when tooling needs refurbishment19. The problems that can occur with optical lens infra-red and special material machining activities, and how they can

be overcome20. The quality controls procedures used, inspection checks that need to be carried out, and the equipment used21. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


465





required)evidence typedate apply checks and practices during the machining activities (all)machine guards in place/ adjusted correctlycomponents are correctly positioned/held securelycutting tools are in suitable conditionoperating program is at correct start pointworkpiece is clear of machine spindlesafe working practices/start up procedures are observedmachine settings are adjusted to maintain accuracyoperate aspheric lens processes (three)glass aspheric generating processglass aspheric polishing processdiamond turning aspheric processdiamond turning diffractive/ hybrid process produce machined optical components that combine different operations (six)centre thickness lens cosmetic defectslens concentricitylens cap heightlens diameter/step feature, anglelens aspheric form analysislens surface roughnesslens power analysis/radiuslens diffractive step heightmachine different types of materials (five)zinc selenideoptical – infra red glass 4gallium arsenideoptical thallium ideobromidezinc sulphideoptical siliconoptical infra red glass 5optical glass aluminiumoptical cleartranoptical infra-red glass 6optical grade germaniumother appropriate optical material


466





required)evidence typedate produce components with dimensional accuracy, form and surface quality to standards (one)BS 4301:1991: optical elements and systemsISO 10110 optical elements and systemsDIN 3140:1978 Pt1-10 preparation of optical elements and drawingsMIL-O-13830 general specification governing manufacture/inspection of optical componentsBS 6001:Pt 1:1991sampling procedures for optical inspectioncarry out necessary checks for accuracy during production (all)lens chamferslens surface finishlens diameterlens cap heightlens centre thicknesslens power errorlens surface power error


Candidate: Date:

Assessor: Date:


467

Unit No 95: Setting NC/CNC Optical Grinding and Polishing Machines for Production

Unit Summary

This unit identifies the competencies you need to prepare and set up optical grinding and polishing Computer Numerical Controlled (CNC) machines, Numerical Controlled (NC) machines or CNC machining centres, in accordance with approved procedures. You will be expected to select the appropriate workholding devices, and to mount and secure them to the machine. You will also be required to select the appropriate cutting tools, to mount and secure them to the appropriate tool holder, and place the cutting tools in the relevant positions within the slides or tool change magazine/carousel.

You will need to ensure that all the tools have been allocated a relevant tool number and that the relevant data on their co-ordinates and datum positions are entered into the operating program and machine. You will also be required to produce tool path information for each set-up, and edit where required. This will involve loading and proving component programs, checking for errors/faults, and editing and saving program changes.

You must produce trial components and prove the machine is working satisfactorily before declaring the machine ready for production. Making adjustments to settings to achieve specification, and solving machine related problems during production, will also form part of your role.


Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting-up procedures used. You will understand the CNC/NC optical machine used, and its application, and know about the workholding devices, tooling, machine operating programs and setting-up procedures, in adequate depth to provide a sound basis for setting up the equipment, correcting faults and ensuring the work output is to the required specification.



468

Unit No 95: Setting NC/CNC Optical Grinding and Polishing Machines for ProductionPerformance statements:



You must:

1. Carry out all the following activities during setting up:• confirm the correct operating programme has been loaded• check the tooling is in a usable condition and appropriate for the operations being performed• ensure the workpiece is correctly positioned and secured without distortion• update programme tool data as applicable• position and adjust machine guards• apply safe working practices

2. Prepare three of the following CNC optical process machines in readiness for production: CNC/NC three axis machineCNC/NC four axis machineCNC polishing machine

CNC optical smoothing machine

CNC optical grinding machineCNC optical edging machine

CNC optical polishing machineCNC special purpose machines

3. Position and secure workpieces using two of the following workholding methods and devices:chucks collets jigs and fixtures fourth axis indexer other

4. Select and mount, in the appropriate tool holding device, three of the following types of cutting tool:form tool roughing tool finishing tool semi finishing tool • half radius toolboring tool profiling tool edging/step tool ceramic finishing tool

5. Prepare the machine for operation by carrying out six of the following activities, as applicable to the machine: positioning tools in the correct position in the tool posts, turrets, magazine or carousel checking tools have a specific tool number in relation to the operating programentering all relevant tool data to the operating program (tool lengths, tool offsets, radius compensation)‘trueing up’ chuck and machining surface if requiredpresetting tooling using setting jigs/fixtures setting tool datums saving changes to programme

6. Machine five different types of materials from the following:germanium silicon • zinc selenide • zinc sulphide • cleartranlanthanum crowns dense flints • flints/light flintsbarium crowns borosilicate crowns • barium dense flintsanomalous dispersion flour crowns other appropriate material

7. Make trial components to prove the machine is operating to required specification, to include all the following:DIN 3140:1978 Pt 1-10 Preparation of optical elements and drawingsBS 4301:1991 Optical elements and systemsISO 10110 Optical elements and systemsMIL-O-13830:1963 General specification governing manufacture and inspection of optical componentsBS 6001:1991 Pt1 Sampling procedures for optical inspection


469

Unit No 95: Setting NC/CNC Optical Grinding and Polishing Machines for ProductionKnowledge statements:


1. The specific safety precautions to be taken when setting up workholding devices and tooling on CNC/NC optical machines

2. How to start and stop the machine in normal and emergency situations3. The importance of ensuring the machine is in safe mode before loading cutting tools and mounting workholding devices.4. The importance of wearing the appropriate protective clothing and equipment, and of keeping the work area clean and

tidy5. The hazards associated with working on CNC/NC machines (such as magnetic tables, moving machinery, automatic

machine operation, lifting and handling workholding devices, and glass and infra-red/special material particles)6. How to handle and store cutting tools, and verify that programs are safe and correct7. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing9. The range of workholding methods and devices that are used on CNC/NC machines10. Why it is important to set the workholding device in relationship to the machine datums and reference points11. The methods of setting the workholding devices and the tools and equipment that can be used12. The range of cutting tools that are used on CNC/NC machines, and typical applications13. How to check that the cutting tools are in a safe and serviceable condition14. Plated bonded, ceramic and diamond bonded tools, and the factors which determine their selection and use (such as

condition of material supplied, hardness of the material, cutting characteristics of the material, tolerances to be achieved, component surface finish and specifications)


16. The advantages of using pre-set tooling, and how to set the tooling using jigs/fixtures17. The use of magazines and carousels, and how to position and identify the tools in relationship to the operating program18. How to place the machine into the correct operating mode, and how to access the program edit facility in order to enter

tooling data (such as tool datums, positions, lengths, offsets and radius compensation) 19. How to conduct trial runs, using single block run, dry run and feed/speed override controls20. The settings that you need to check before allowing the machine to operate in full program run mode21. How the various types of materials used will affect the feeds and speeds that can be used22. The application of cutting fluids in relationship to a range of materials been machined23. Typical problems that can occur with the setting up of the tooling and workholding devices, and what to do if they occur24. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


470





required)evidence typedate carry out activities during setting up (all)confirm correct operating programme has been loadedcheck tooling is in suitable condition/appropriate for operations being performedensure workpiece is correctly positioned/securedupdate programme tool dataposition/adjust machine guardsapply safe working practicesprepare CNC optical process machines in readiness for production (three)CNC/NC three axis machineCNC/NC four axis machineCNC polishing machineCNC optical smoothing machineCNC optical grinding machineCNC optical edging machineCNC optical polishing machineCNC special purpose machinesposition and secure workpiece using workholding methods and devices (two)chuckscolletsjigs and fixturesfourth axis indexerotherselect and mount, in the appropriate tool holding device types of cutting tool (three)form toolboring toolroughing tool profiling toolfinishing tooledging/step toolsemi finishing toolceramic finishing toolhalf radius toolprepare the machine for operation by carrying out activities (six)positioning tools in correct position in tool posts/turrets/ magazines or carouselchecking tools specific numberentering all relevant data‘trueing up’ chuck and machining surfacepresetting tooling using setting jigs/fixturessetting tool datumssaving changes to programme


471





required)evidence typedate machine different types of materials (five)germaniumlanthanum crownsbarium crowns anomalous dispersion flour crownssilicon dense flintsborosilicate crownszinc selenidezinc sulphideflints/light flintsbarium dense flintscleartranother appropriate materialmake trial components to prove machine is operating to required specification (all)DIN 3140:1978 Pt 1-10 preparation of optical elements and drawingsBS 4301:1991 optical elements and systemsISO 10110 optical elements and systemsMIL-O-13830:1963 general specification governing manufacture/inspection of optical componentsBS 6001:1991 Pt 1 sampling procedures for optical inspection


Candidate: Date:

Assessor: Date:


472

Unit No 96: Machining Components using NC/CNC Optical Grinding and PolishingMachines

Unit Summary

This unit identifies the competencies you need to machine glass and infra-red/special material components, using NC/CNC optical grinding and polishing machines, in accordance with approved procedures. You will be required to produce a range of components of various infra-red and visible materials, which combine a range of different features such as surface finish, cap height, diameters, bevels, profiles, parallelism, optical power and form analysis.

You will be required to check and verify finished components using various metrology equipment to ensure they meet the required specifications.


Your responsibilities will require you to comply with organisational policy and procedures for the optical machining activities undertaken, and to report any problems with the optical machining activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking full responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying optical machining procedures. You will understand the glass and infra-red/special materials, CNC/NC optical processes, and their application, and will know about the equipment, materials and consumables, in adequate depth to provide a sound basis for carrying out the activities to the required specification.



473



You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Confirm that the equipment is set up and ready for operationc. Follow the defined procedures for starting and running the operating systemd. Deal promptly and effectively with error messages or equipment faults that are within your control and report those that cannot be solvede. Control the computer process and ensure that the production output is to the required specificationf. Shut down the equipment to a safe condition on conclusion of the activities



• the workpiece is correctly positioned and secured• the workpiece is clear of the machine spindle

● operating program is at the correct start point ● tooling is in a usable condition

• machine guards are in place and correctly adjusted and positioned• safe working practices and startup procedures are observed• machine settings are adjusted as required to maintain accuracy

2. Operate three of the following CNC/NC optical process machines:CNC/NC 3 axis machine CNC generating machine CNC optical edging machineCNC/NC 4 axis machine CNC smoothing machine CNC optical grinding machineCNC polishing machine CNC special purpose machines

3. Produce optical machined components which combine different operations and cover five of the following: centre thickness bevels optical form analysissurface finish component profile optical power (radius of curvature)cap height concentricity diameter/step feature, angles

4. Machine five different types of materials from the following: germanium silicon zinc selenide zinc sulphide cleartranlanthanum crowns dense flints flints/light flintsbarium crowns borosilicate crowns barium dense flintsanomalous dispersion flour crowns other appropriate material

5. Produce components with dimensional accuracy, form and surface quality, to one of the following standards applicable to the operations.

DIN 3140:1978 Pt 1-10 Preparation of optical elements and drawingsBS 4301:1991 Optical elements and systemsISO 10110 Optical elements and systemsMIL-O-13830:1963 General specification governing manufacture and inspection of optical componentsBS 6001:1991 Pt1 Sampling procedures for optical inspection

6. Carry out the necessary checks for accuracy during production of five of the following:centre thickness component surface finish component cosmetic defectscomponent profiles bevels/chamfers lens diametersurface power error surface form error angles cap height


474




1. The safe working practices and procedures that need to be followed while operating CNC/NC optical grinding and polishing machines/machining centres


emergency4. The personal protective equipment that needs to be worn, and where this can be obtained 5. The hazards associated with CNC/NC process operations, and how they can be minimised6. The importance of keeping the work area clean and tidy7. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing9. The relationship between the design and manufacture of optical CNC/NC components10. The process methods of CNC/NC optical manufacture, and the use of a variety of tools (including diamond tip tools,

diamond abrasive wheels and polishing tools)11. The optical component mounting methods used to set up the workpiece prior to operation, to minimise wedge

error, concentricity and astigmatism12. The effect of backlash in machines slides, dials and screws, and how this can be overcome13. How to handle and store all cutting tools and kit required, safely and correctly14. The factors that affect the selection of cutting feeds pressures, speeds required and the depth of cut that can be

taken (based on workpiece rigidity, machine condition, types of tooling used, material used, finish and tolerance required)

15. How tool wear affects surface finish and dimensional accuracy16. How the various types of materials will affect the way the operation is performed17. The application of cutting fluids with regard to the range of material being produced18. How to recognise machine faults and identify when tooling needs refurbishment19. The problems that can occur with optical component glass and infra-red/special material machining activities,and

how they can be overcome20. The quality control procedures used, inspection checks that need to be carried out, and the equipment used21. The extent of your own responsibility and whom you should report to if you have problems that you cannot

resolve


475





required)evidence typedate confirm that machine is ready for operation by checking (all)workpiece is correctly positioned/securedworkpiece is clear of machine spindlemachine guards are in place/correctly adjusted/ positionedsafe working practices/startup procedures are observedmachine settings adjusted to maintain accuracyoperating program is at correct start pointtooling is in usable conditionoperate CNC/NC optical process machines (three)CNC/NC 3 axis machineCNC/NC 4 axis machineCNC polishing machineCNC generating machineCNC smoothing machineCNC special purpose machinesCNC optical edging machineCNC optical grinding machineproduce optical machined components which combine different operations and cover (five)centre thicknesssurface finishcap heightbevelscomponent profileconcentricityoptical form analysisoptical powerdiameter/step feature, anglesmachine different types of materials (five)germaniumlanthanum crownsbarium crownsanamalous dispersion flour crownssiliconzinc selenidedense flintsborosilicate crownszinc sulphideflints/light flintsbarium dense flintsother appropriate material cleartran



476


required)evidence typedate produce components with dimensional accuracy, form and surface quality to standards (one)DIN 3140:1978 Pt 1-10 preparation of optical elements and drawingsBS 4301:1991 optical elements and systemsISO 10110 optical elements and systemsMIL-O-13830:1963 general specification governing manufacture/inspection of optical componentsBS 6001:1991 Pt 1 sampling procedures for optical inspectioncarry out necessary checks for accuracy during production (five)centre thicknesscomponent profilessurface power errorcomponent surface finishbevels/chamferssurface form errorcomponent cosmetic defectslens diameteranglescap height


Candidate: Date:

Assessor: Date:


477

Unit No 97: Machining Optical Cylinders and Domes

Unit Summary

This unit identifies the competencies you need to carry out machining and hand finishing operations on optical cylinders and domes, in accordance with approved procedures, using optical process machines.

For domes, you will be required to machine components that combine a mixture of processes identified for optical domes, using a selection of specified optical dome materials. You will be expected to produce a range of components that combine a number of different features, such as centre thickness, diameters, generated blanks, optical form, and optical power (radius of curvature).

For cylinders, you need to carry out optical cylinder processing in accordance with optical approved procedures, including hand preparation, and smoothing and polishing, using a selection of specified optical cylinder materials. You will be expected to produce a range of cylinder components that combine different features such as centre thickness, angles, axis, blocking, parallelism, and optical power and form error.

You will be required to set up and operate the machines in line with safe working practices and approved procedures, and to continuously monitor the machining operations, making any necessary adjustments in order to ensure that the work output is to the required quality and accuracy. Meeting production targets will be an important issue, and your production records must show consistent and satisfactory performance.

Your responsibilities will require you to comply with organisational policy and procedures for the optical machining activities undertaken, and to report any problems with the optical machining activities, materials or equipment used that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying optical machining procedures. You will understand the optical cylinder and dome materials, the processes used, and their application and will know about the setting-up procedures, equipment, materials and consumables, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the work output is to the required specification.



478

Unit No 97: Machining Optical Cylinders and DomesPerformance statements:



You must:1. Carry out all the following activities during the setting up and machining activities:

ensure appropriate machine guards are in place and correctly adjustedhold the components securely without damage or distortionensure tooling is appropriate for the operations and is maintained in a suitable conditionset the tooling and machine operating parameters to achieve component specificationadjust the machine settings as required during the machining activities to maintain component accuracyapply safe working practices at all times

2. Either Set up and operate all of the following types of optical cylinder processes: cylinder preparation processcylinder pitch polishing processcylinder hand lapping to axis/angle processcylinder silk polishing process cylindrical test plate manufacture process

Or Set up and operate four of the following types of optical dome processes:dome preparation processdome silk polishing processdome surface generation processdome pitch polishing processdome polyurethane process

3. Produce machined optical components that combine different operations and cover six of the following:cylinder/dome centre thicknesscylinder/dome concentricitycylinder/dome cosmetic defectscylinder/dome diametercylinder/dome truncationdome preparation/smoothing process

cylinder/dome surface generationcylinder/dome power analysis (radius)cylinder/dome form error analysiscylinder parallelismcylinder hand lapping processdome transmitted wave-front analysisdome transmission analysis

4. Either Machine four different types of cylinder materials from the following:germaniumbarium crownsdense flintsflints/light flintslanthanum crownsbarium dense flintsoptical neutral density cut glass

anomalous dispersion flour crownsoptical orange filter glassoptical blue filter glassborosilicate crownsmagnesium fluorideother appropriate material

Or Machine two different types of dome materials from the following: germaniumzinc selenidezinc sulphide

magnesium fluorideother


479

5. Produce components with dimensional accuracy, form and surface quality, to one of the following standards applicable to the operations:

DIN 3140:1978 Pt 1-10 Preparation of optical elements and drawingsBS 4301:1991 Optical elements and systemsISO 10110 Optical elements and systemsMIL-O-13830:1963 General specification governing manufacture and inspection of optical componentsBS 6001:1991 Pt1 Sampling procedures for optical inspection

6. Carry out the necessary checks for accuracy during production of at least five of the following:dome diametercylinder parallelismcylinder/dome truncation

cylinder/dome bevelscylinder/dome chamferscylinder/dome cap height

cylinder/dome centre thickness cylinder/dome cosmetic surface finishes

cylinder/dome surface power errorcylinder/dome surface form error


480

Unit No 97: Machining Optical Cylinders and DomesKnowledge statements:


1. The safe working practices and procedures that need to be followed while operating optical cylinder/dome, generating, hand lapping, smoothing and polishing equipment


emergency4. The personal protective equipment that needs to be worn, and where this can be obtained5. The hazards associated with optical cylinder/dome process operations, and how they can be minimised6. The importance of keeping the work area clean and tidy 7. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing9. The various optical cylinder/dome operations that can be performed, and the shapes and types of tooling that can

be used (dome diamond abrasive wheels, dome polyurethane polishers, cylinder/dome pitch- polishers and silk polishers and smoothing tools)

10. The methods that can be used to set up the workpiece prior to the operation, to minimise optical wedge and parallelism in relation to the cutting tool

11. The effect of backlash in machines slides, dials and screws, and how this can be overcome12. How to handle and store all cutting tools and kit required, safe and correctly13. Factors which affect the selection of dome cutting feeds, cylinder/dome pressures and speeds required and dome

depth of cuts that can be taken (such as workpiece rigidity, machine condition, types of tooling used, material used, finish and tolerance required)

14. How tool wear affects surface finish and dimensional accuracy15. How the various types of materials will affect the way the operation is performed16. The application of cutting fluids and polishing mediums with regard to the range of material being produced17. The effect of clamping the workpiece, and how this can cause distortion in the finished component18. How to recognise machine faults and identify when tooling needs refurbishment 19. The sorts of problems that can occur with optical cylinder/dome machining activities, and how they can be

overcome20. The quality control procedures used, inspection checks that need to be carried out, and the equipment used21. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve.


481





required)evidence typedate carry out activities during the setting up and machine activities(all)ensure appropriate machine guards are in place/correctly adjustedhold components securely without damage/distortionensure tooling is appropriate for operations/maintained in a suitable conditionset tooling/machine operating parameters to achieve component specificationadjust the machine settingsapply safe working practiceseither set up types of optical cylinder processes (all)cylinder preparation processcylinder pitch polishing processcylinder hand lapping to axis /angle processcylinder silk polishingcylindrical test plate manufacture processor set up types of optical dome processes (four)dome preparation processdome silk polishing processdome surface generation processdome pitch polishing processdome polyurethane processproduce machined optical components that combine different operations (six)cylinder/dome centre thicknesscylinder/dome concentricitycylinder/dome cosmetic defectscylinder/dome diametercylinder/dome truncationdome preparation/smoothing processcylinder/dome surface generationcylinder/dome power analysiscylinder/dome form error analysiscylinder parallelismcylinder hand lapping processdome transmitted wave front analysisdome transmission analysis


Candidate: Date:

Assessor: Date:

Unit No 98: Vacuum Coating Optical Materials


482

Unit No 98: Vacuum Coating Optical Materials

Unit Summary

This unit identifies the competencies you need to carry out optical thin-film coating operations, in accordance with approved procedures, using optical thin-film coating process machines. You will be required to set up and use a range of equipment, in order to produce components that combine a mixture of processes identified for optical thin-film coating, using a selection of specified optical materials. You will be expected to produce a range of components that combine a number of different features, such as optical transmission, flatness, surface defects and transmitted wavelength.

You will be required to set up and operate the coating machine in line with safe working practices and approved procedures, and to continuously monitor the coating machining operations, making any necessary adjustments in order to ensure that the work output is to the required quality and accuracy. Meeting production targets will be an important issue, and your production records must show consistent and satisfactory performance.

Your responsibilities will require you to comply with organisational policy and procedures for the optical coating activities undertaken, and to report any problems with the coating activities, materials or equipment that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying optical coating procedures. You will understand the optical thin-film coating processes, and their application, and will know about the equipment, materials and consumables, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the work output is to the required specification.



483

Unit No 98: Vacuum Coating Optical MaterialsPerformance statements:

You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Ensure the material surfaces to be treated are suitably prepared for the finishing operations to be carried outc. Check that the finishing equipment and treatment solutions are set up and maintained at satisfactory

operating conditions and levelsd. Carry out the treatment process in accordance with operating procedures and the component specification requirementse. Ensure that the treated workpiece achieves the required characteristics and meets the finishing specificationf. Deal promptly and effectively with problems within your control and report those that cannot be solvedg. Dispose of waste and excess materials in line with agreed organisational proceduresh. Shut down the finishing equipment to a safe condition on completion of the processing activities


You must:1. Carry out all of the following activities during the setting up and operating activities:

use the correct issue production documentation (drawings, manuals, specifications, job cards)use relevant health and safety documentation (material data sheets, COSHH sheets, risk assessments)ensure appropriate machine guards are in place and correctly adjustedhold the components securely without damage or distortionset the machine operating parameters to achieve the component specificationadjust machine settings as required to maintain component accuracy apply safe working practices at all times

2. Set up and operate three of the following types of optical thin film coating process machines from the following:infra-red/special material coatingvisible dichroics/edge filters coatinggraded combiners coating

polycarbonate material coatingbasic anti-reflection coatingother coating processes

3. Produce optical thin-film coated components that combine different operations and cover all of the following:prepare coating tooling clean coating tooling prepare coating material sourcesprepare coating components for coating operationclean coating components before and after coating operation

load coating components unload coating components

4. Thin-film coat four different types of component materials from the following:germaniumpolycarbonatebarium crowndense flintsoptical blue filter glass

zinc selenide prisms and flatsborosilicate crownflint/light flintsanomalous dispersion flour crownoptical neutral density glass

zinc sulphide prisms and flatsbarium dense flintslanthanum crownsoptical orange filter glassother appropriate material

5. Produce components with dimensional accuracy, form and surface quality, to one of the following standards applicable to the operations:

DIN 3140:1978 Pt 1-10 Preparation of optical elements and drawingsMIL-O-13830:1963 General specification governing manufacture and inspection of optical componentsBS 4301:1991 Optical elements and systems ISO 10110 Optical elements and

systemsBS 6001:1991 Pt1 Sampling procedures for optical inspection optical coating specifications

6. Carry out the necessary checks for accuracy during production of all of the following:transmission measurementsurface defect measurement

flatness measurement coating adhesion testcoating humidity test


484

Unit No 98: Vacuum Coating Optical MaterialsKnowledge statements:


1. The safe working practices and procedures that need to be followed while operating optical coating process machines2. The safety mechanisms on the machine, and the procedure for checking that they function correctly3. The operation of the machine controls in both set-up and run modes, and how to stop the machine in an emergency4. The personal protective equipment that needs to be worn, and were this can be obtained5. The hazards associated with optical coating process operations, and how they can be minimised6. The importance of keeping the work area clean and tidy7. Where to obtain the component drawings, specifications and/or job instructions, in order to produce the required

components to be coated8. How to extract the necessary information from the drawings and specifications, in order to produce the required

optical coating component9. The factors which effect the selection of machine set-up, in order to achieve correct coating specification10. The preparation of coating material sources11. How to load and unload coating components correctly into coating jigs and fixtures12. How to clean and store coated components prior to coating operations13. How to prepare the coating plant prior to the coating process14. How to correctly identify the component face to be coated15. How to strip the coating plant after coating operations have been carried out16. The problems that can occur with optical thin-film coating activities, and how they can be overcome17. The quality control procedures used, inspection checks that need to be carried out, and the equipment used to achieve

the required component18. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


485





required)evidence typedate carry out activities during the setting up and operating activities (all)use the correct issue production documentationuse relevant health and safety documentationensure appropriate machine guards are in place/correctly adjustedhold the components securelyset machine operating parameters to achieve component specificationadjust machine settings to maintain component accuracyapply safe working practicesset up and operate types of optical thin film coating process machines (three)infra-red/special material coatingvisible dichroics/edge filters coatinggraded combiners coatingpolycarbonate material coatingbasic anti-reflection coatingother coating processesproduce optical thin-film coated components that combine different operations (all)prepare coating tooling prepare coating component for coating operationclean coating components before/after coating operationprepare coating material sourcesload coating componentsunload coating componentsthin-film coat different types of component materials (four)germaniumpolycarbonatebarium crowndense flintsoptical blue filter glasszinc selenide prisms and flatsborosilicate crownflint/light flintsanomalous dispersion flour crownoptical neutral density glasszinc sulphide prisms and flatsbarium dense flintslanthanum crownsoptical orange filter glassother appropriate material






486

required)evidence typedate produce components with dimensional accuracy, form and surface quality to standards (one)DIN 3140:1978 Pt 1-10 preparation of optical elements and drawingsMIL-O-13830:1963 general specification governing manufacture/inspection of optical componentsBS 4301:1991optical elementsand systemsBS 6001:1991 Pt 1 sampling procedures for optical inspectionISO 10110 optical elements and systemsoptical coating specificationscarry out necessary checks for accuracy during production (all)transmission measurementsurface defect measurementflatness measurementcoating adhesion testcoating humidity test


Candidate: Date:

Assessor: Date:


487

Unit No 99: Machining Optical Plastic Components

Unit Summary

This unit identifies the competencies you need to carry out machining operations on optical plastic materials, in accordance with approved procedures, using optical plastic process machines. You will be required to set up and operate a range of machines, in order to produce components that combine a mixture of processes identified for plastic materials, using a selection of specified optical plastic lens and flat materials. You will be expected to produce a range of components that combine a number of different features, such as centre thickness, diameters, generated blanks, optical lens form, power, and stress and strain analysis.

You will be required to set up and operate the machine in line with safe working practices and approved procedures, and to continuously monitor the machining operations, making any necessary adjustments in order to ensure that the work output is to the required quality and accuracy. Meeting production targets will be an important issue, and your production records must show consistent and satisfactory performance.

Your responsibilities will require you to comply with organisational policy and procedures for the optical machining activities undertaken, and to report any problems with the setting-up procedures, optical machining activities, materials or equipment used, that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying optical plastic machining procedures. You will understand the optical machining processes used, and their application, and be familiar with the equipment, materials and consumables, in adequate depth to provide a sound basis for setting up the equipment, carrying out the activities, correcting faults and ensuring the work output is to the required specification.



488

Unit No 99: Machining Optical Plastic ComponentsPerformance statements:



You must:1. Carry out all the following activities during setting up and operating of the machines:

ensure appropriate machine guards are in place and correctly adjustedhold the components securely without damage or distortionensure tooling is appropriate for the operations and is maintained in a suitable conditionset the tooling and machine operating parameters to achieve component specificationadjust machine settings as required during the machining activities to maintain component accuracyapply safe working practices at all times

2. Set up and operate five types of optical plastic processes from the following:automated processlens generating processlens edging processlens smoothing process

prism/flat smoothing processhand smooth processhand polish processplastic stabilisation process

plastic diamond turning processprism/flat polishing processoptical special materials processspecial plastic cleaning process

3. Produce machined optical components that combine different operations and cover six of the following: centre thickness flat parallelism lens surface generation angular collimatinglens diameterlens concentricity

lens form analysislens power analysis

lens cosmetic defectslens truncation and cap height

4. Machine one of the following types of plastic material: polyethyrene sulfones polycarbonatecyclic olefin

polyetherimideacrylicnylon other optical grade plastics

5. Produce components with dimensional accuracy, form and surface quality to one of the following standards: BS 4301 1991: Optical elements and systemsISO 10110 Optical elements and systemsDIN 3140:1978 Pt1-10 Preparation of optical elements and drawingsMIL-O-13830:1963 General specification governing manufacture and inspection of optical componentsBS 6001:Pt1 .1991: Sampling procedures for optical inspectionBS 8888:2000: Engineering drawing practice

6. Carry out the necessary checks for accuracy during production of a least five of the following:lens chamferslens surface finish

lens diameterlens cap height

lens centre thicknessprism angles

parallelismtruncations

lens surface form error bevels lens surface power/radius error


489

Unit No 99: Machining Optical Plastic ComponentsKnowledge statements:


1. The safe working practices and procedures that need to be followed while operating plastic lens, generating, and smoothing and polishing equipment


emergency4. The personal protective equipment that needs to be worn, and where this can be obtained5. The hazards associated with plastic lens process operations, and how they can be minimised6. The importance of keeping the work area clean and tidy7. How to use and extract information from engineering drawings and related specifications, to include symbols and


points and system of tolerancing9. The various plastic prism/lens operations that can be performed, and the shapes and types of tooling that can be

used (fly cutters, diamond abrasive wheels, polyurethane polishers, pitch polishers)10. The methods that can be used to set up the workpiece prior to the operation, to minimise optical wedge and

parallelism in relation to the cutting tool11. What plastics do in their respective parts and make up12. Achieving the required level of finish using hand smoothing and polishing techniques13. The effect of backlash in machines slides, dials and screws, and how this can be overcome14. How to handle and store all cutting tools and kit required, safe and correctly15. Factors which affect the selection of cutting feeds, pressures and speeds required and the depth of cut that can be

taken (such as workpiece rigidity, machine condition, types of tooling used, material used, finish and tolerance required)

16. How tool wear affects surface finish and dimensional accuracy17. How the various types of materials will affect the way the operation is performed18. The application of cutting fluids with regard to the range of material being produced19. The effect of clamping the workpiece, and how this can cause distortion in the finished component20. How to recognise machine faults and identify when tooling needs refurbishment21. The problems that can occur with plastic lens/prism machining activities, and how they can be overcome22. The quality controls procedures used, inspection checks that need to be carried out, and the equipment used23. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve


490





required)evidence typedate carry out activities during setting up and operating of the machines (all)ensure appropriate machine guards are in place/correctly adjustedhold components securely without damage/distortionensure tooling is appropriate for operations/maintained in a suitable conditionset tooling/machine operating parameters to achieve component specificationadjust machine settings during machining activities to maintain component accuracyapply safe working practicesset up and operate types of optical plastic processes automated processlens generating processlens edging processlens smoothing processprism/flat smoothing processhand smooth processhand polish processplastic stabilisation processplastic diamond turning processprism/flat polishing processoptical special materials processspecial plastic cleaning processproduce machined optical components that combine different operations (six)centre thicknesslens diameterlens concentricityflat parallelismlens form analysislens power analysislens surface generation lens cosmetic defectslens truncation and cap heightangular collimatingmachine types of plastic material (one)cyclic olefinpolyetherimideacrylicnylonpolyethyreneother optical grade plasticssulfonespolycarbonate






491

required)evidence typedate produce components with dimensional accuracy, form and surface quality to standards (one)BS 4301 1991: optical elements and systemsISO 10110 optical elements and drawingsDIN 3140:1978 Pt 1-10 preparation of optical elements and systemsMIL-O-13830: 1963 general specification governing manufacture and inspection of optical componentsBS 6001:Pt 1 1991: sampling procedures for optical inspectionBS 8888:2000 engineering drawing practicecarry out necessary checks for accuracy during production (all)lens chamfers lens surface finishlens surface form errorlens diameterlens cap heightbevelslens centre thicknessprism angleslens surface power/radius errorparallelismtruncations


Candidate: Date:

Assessor: Date:


492

Mechanical Manufacturing Engineering Level 3

Opportunities for generation of Key Skills evidence:

The Level 3 award in Mechanical Manufacturing Engineering has been contextualised by EMTA from the National Engineering Competency Standards (ECS). The following table lists the opportunities for generation of Key Skills evidence for each unit in the award and also gives reference to the ECS unit it has been derived from.

Key Skills ReferenceMechanical Manufacturing Engineering Unit ECS Unit Communication Application of

NumberProblem Solving

1 Complying with StatutoryRegulations and Organisational Safety Requirements

N/A

2 Using and Interpreting Engineering Drawings and Documents

1.13 C2.1aC2.2

N2.1 PS1.1PS1.2PS1.3

3 Working Efficiently and Effectively in Engineering

N/A

Unit 4: Setting Centre Lathes for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 5: Machining Components using Centre Lathes

3.04 C1.1C2.2

PS1.1PS1.2PS1.3

Unit 6: Setting Turret Lathes for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 7: Machining Components using Turret Lathes

3.04 C1.1C2.2

PS1.1PS1.2PS1.3

Unit 8: Setting Milling Machines for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 9: Machining Components using Milling Machines

3.04 C1.1C2.2

PS1.1PS1.2PS1.3

Unit 10: Setting Shaping, Planing or Slotting Machines for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 11: Machining Components using Shaping, Planing or Slotting Machines

3.04 C1.1C2.2

PS1.1PS1.2PS1.3

Unit 12: Setting Gear Cutting Machines for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 13: Machining Components using Gear Cutting Machines

3.04 C1.1C2.2

PS1.1PS1.2PS1.3


493

Key Skills ReferenceMechanical Manufacturing Engineering Unit ECS Unit Communication Application

of NumberProblem Solving

Unit 14: Setting Gear Grinding Machines for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 15: Machining Components using Gear Grinding Machines

3.04 C1.1C2.2

PS1.1PS1.2PS1.3

Unit 16: Setting Horizontal Boring Machines for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 17: Machining Components using Horizontal Boring Machines

3.04 C1.1C2.2

PS1.1PS1.2PS1.3

Unit 18: Setting Vertical Boring Machines for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 19: Machining Components using Vertical Boring Machines

3.04 C1.1C2.2

PS1.1PS1.2PS1.3

Unit 20: Setting Electro Discharge Machines for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 21: Machining Components using Electro Discharge Machines

3.04 C1.1C2.2

PS1.1PS1.2PS1.3

Unit 22: Setting Grinding Machines for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 23: Machining Components using Grinding Machines

3.04 C1.1C2.2

PS1.1PS1.2PS1.3

Unit 24: Setting Honing and Lapping Machines for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 25: Machining Components using Honing and Lapping Machines

3.04 C1.1C2.2

PS1.1PS1.2PS1.3

Unit 26: Setting Broaching Machines for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 27: Machining Components using Broaching Machines

3.04 C1.1C2.2

PS1.1PS1.2PS1.3

Unit 28: Setting Metal Spinning Machines for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3


494



Unit 29: Producing Components using Metal Spinning Machines

3.04 C1.1C2.2

PS1.1PS1.2PS1.3

Unit 30: Loading and Proving NC/CNC Machine Tool Programs

2.17 C2.1aC2.3

PS1.1PS1.2PS1.3

Unit 31: Carrying Out CNC Machine Tool Programming

2.17 C2.1aC2.3

PS1.1PS1.2PS1.3

Unit 32: Setting NC/CNC Turning Machines for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 33: Machining Components using NC/CNC Turning Machines

3.01 C1.1C2.2

PS1.1PS1.2PS1.3

Unit 34: Setting NC/CNC Milling Machines for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 35: Machining Components using NC/CNC Milling Machines

3.01 C1.1C2.2

PS1.1PS1.2PS1.3

Unit 36: Setting NC/CNC Grinding Machines for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 37: Machining Components using NC/CNC Grinding Machines

3.01 C1.1C2.2

PS1.1PS1.2PS1.3

Unit 38: Setting NC/CNC Punching Machines for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 39: Machining Components using NC/CNC Punching Machines

3.01 C1.1C2.2

PS1.1PS1.2PS1.3

Unit 40: Setting NC/CNC Laser Profiling Machines for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 41: Machining Components using NC/CNC Laser Profiling Machines

3.01 C1.1C2.2

PS1.1PS1.2PS1.3

Unit 42: Setting NC/CNC Electro Discharge Machines for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 43: Machining Components using NC/CNC Electro Discharge Machines

3.01 C1.1C2.2

PS1.1PS1.2PS1.3


495



Unit 44: Setting NC/CNC Vertical Boring Machines for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 45: Machining Components using NC/CNC Vertical Boring Machines

3.01 C1.1C2.2

PS1.1PS1.2PS1.3

Unit 46: Setting NC/CNC Horizontal Boring Machines for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 47: Machining Components using NC/CNC Horizontal Boring Machines

3.01 C1.1C2.2

PS1.1PS1.2PS1.3

Unit 48: Setting NC/CNC Gear Cutting Machines for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 49: Machining Components using NC/CNC Gear Cutting Machines

3.01 C1.1C2.2

PS1.1PS1.2PS1.3

Unit 50: Setting NC/CNC Machining Centres for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 51: Machining Components using NC/CNC Machining Centres

3.01 C1.1C2.2

PS1.1PS1.2PS1.3

Unit 52: Handing Over Machine Tools to Production Operators

N/A

Unit 53: Setting Capstan and Turret Lathes for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 54: Setting Single-Spindle Automatic Turning Machines for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 55: Setting Multi-Spindle Automatic Turning Machines for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 56: Setting Single and Multi-Spindle Drilling Machines for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 57: Setting Tool and Cutter Grinding Machines for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 58: Setting Special-Purpose Machines for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 59: Setting Power Presses for Production

3.06 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3


496



Unit 60: Producing Components using Hand Fitting Techniques

3.03 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

Unit 61: Assembling Mechanical Products

3.12 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

Unit 62: Producing Components by Manual Machining

3.04 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

Unit 63: Fitting Fluid Power Components to Mechanical Assemblies

3.12 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

Unit 64: Fitting Pipework Systems to Mechanical Assemblies

3.12 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

Unit 65: Fitting Electrical/Electronic Components to Mechanical Assemblies

3.12 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

Unit 66: Producing Power Turbine Combustion Assemblies

3.12 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

Unit 67: Producing Power Turbine Compressor Assemblies

3.12 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

Unit 68: Producing Turbine Assemblies

3.12 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

Unit 69: Producing Turbine Gearbox Assemblies

3.12 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

Unit 70: Producing Turbine Major Assemblies

3.12 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

Unit 71: Producing Piston Engine Assemblies

3.12 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

Unit 72 Repairing and Modifying Mechanical Assemblies

N/A

Unit 73:Checking Completed Assemblies Comply with Specification

6.01 C1.1C1.3C2.2

N2.1 PS1.1PS1.2PS1.3

Unit 74: Pipe Bending and Forming by Hand Methods

3.16 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

Unit 75: Pipe Bending and Forming using Bending Machines

3.01 C1.1C2.2

PS1.1PS1.2PS1.3


497



Unit 76: Assembling Screwed Pipework

3.12 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

Unit 77: Assembling Small Bore Non-Ferrous Pipework

3.12 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

Unit 78: Assembling Non-Metallic Pipework

3.12 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

Unit 79: Preparing and Testing Pipework Systems

6.02 C2.2

Unit 80: Producing Socket and Flange Fillet Welded Joints in Pipe using a Manual Welding Process

3.09 C1.1C2.2

PS1.1PS1.2PS1.3

Unit 81: Producing Composite Mouldings using Pre-Preg Laminating Techniques

3.05 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

Unit 82: Producing Composite Mouldings using Wet Lay-up Techniques

3.05 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

Unit 83: Producing Composite Assemblies

3.12 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

Unit 84: Bonding Composite Mouldings

3.11 C1.1C2.2

PS1.1PS1.2PS1.3

Unit 85: Repairing Composite Mouldings

5.06 C1.3C2.2

Unit 86: Applying Finishes to Composite Mouldings

3.14 C1.1C2.2

PS1.1PS1.2PS1.3

Unit 87: Trimming Composite Mouldings using Hand Tools

3.03 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

Unit 88: Identifying Defects in Composite Mouldings

5.07 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2

Unit 89: Inspecting Optical Components

6.06 C1.1C1.3C2.2

N2.1 PS1.1PS1.2PS1.3

Unit 90: Machining Infra-red/Special Material Lenses

3.04 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

Unit 91: Machining Optical Glass Lenses

3.04 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3


498



Unit 92: Machining Optical Prism and Flat Components

3.04 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

Unit 93: Setting CNC Aspheric Glass and Diamond Turning Machines

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 94: Machining Components using CNC Aspheric Glass and Diamond Turning Machines

3.01 C1.1C2.2

PS1.1PS1.2PS1.3

Unit 95: Setting NC/CNC Optical Grinding and Polishing Machines for Production

2.01 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

Unit 96: Machining Components using NC/CNC Optical Grinding and Polishing Machines

3.02 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

Unit 97: Machining Optical Cylinders and Domes

3.04 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

Unit 98: Vacuum Coating Optical Materials

3.14 C1.1C2.2

PS1.1PS1.2PS1.3

Unit 99: Machining Optical Plastic Components

3.04 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3


499

Further information

Further information regarding centre/scheme approval or any aspect of assessment of the NVQs should be referred to the relevant City & Guilds regional/national office:

Region Telephone Facsimile

City & Guilds Scotland 0131 226 1556 0131 226 1558

City & Guilds North East 0191 402 5100 0191 402 5101

City & Guilds North West 01925 897900 01925 897925

City & Guilds Yorkshire 0113 380 8500 0113 380 8525

City & Guilds Wales 02920 748600 02920 748625

City & Guilds West Midlands 0121 359 6667 0121 359 7734

City & Guilds East Midlands 01773 842900 01773 833030

City & Guilds South West 01823 722200 01823 444231

City & Guilds London and South East

020 7294 2820 020 7294 2419

City & Guilds Southern 020 7294 2724 020 7294 2412

City & Guilds East 01480 308300 01480 308325

City & Guilds Northern Ireland/ Ireland

028 9032 5689 028 9031 2917

City & Guilds Head Office –Customer Service Enquiry Unit

020 7294 2800 020 7294 2400

Website http://www.city-and-guilds.co.uk

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