contents setter - milling.pdf · this unit covers setting of computer numerically controlled (cnc)...

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1. Introduction and Contacts..…[Insert Page no.]

2. Qualifications Pack……….……...[Insert Page no.]

3. OS Units……………………..…….….[Insert Page no.]

4. Glossary of Key Terms …………[Insert Page no.]

5. Annexure: Nomenclature for QP & OS. [Insert

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OS describe what

individuals need to do, know and understand in order to carry out a particular job role or function

OS are

performance standards that individuals must achieve when carrying out functions in the workplace, together with specifications of the underpinning knowledge and understanding

Capital Goods Skill Council, FICCI, Federation House, Tansen Marg, New Delhi 110 001

E-mail: [email protected]

SECTOR: CAPITAL GOODS

SUB-SECTOR: 1. Machine Tools 2. Tools Dies and Press Tools 3. Plastic Manufacturing Machinery 4. Textile Manufacturing Machinery

5. Process Plant Machinery 6. Electrical and Power Machinery 7. Light Engineering

OCCUPATION: Machining

REFERENCE ID: CSC/ Q 0120

CNC Setter - Milling: This unit covers setting of computer numerically controlled (CNC) milling machines, in order to perform milling operations on metal components, as per specifications provided.

Brief Job Description: It involves removal of metal from the outer diameter of a rotating cylindrical workpiece. It also involves inspecting the components and continuously monitoring of the machining operations and making minor adjustments in order to ensure that the work output is to the required quality and accuracy. Personal Attributes: Basic communication, numerical and computational abilities. Openness to learning, ability to plan and organize own work and identify and solve problems in the course of working. Understanding the need to take initiative and manage self and work to improve efficiency and effectiveness

Introduction

Qualifications Pack: CNC Setter - Milling

elpdesk Attendant

QUALIFICATIONS PACK - OCCUPATIONAL STANDARDS FOR CAPITAL GOODS INDUSTRY

Insert SSC logo height – 0.51”, width 2.84”

Qualifications Pack For CNC Setter - Milling

Qualifications Pack Code CSC/ Q 0120

Job Role CNC Setter - Milling

Credits(NVEQF/NVQF/NSQF) [OPTIONAL] TBD Version number 1.0

Sector CAPITAL GOODS Drafted on 14/03/14

Sub-sector

1. Machine Tools 2. Tools Dies And Press Tools 3. Plastic Manufacturing

Machinery 4. Textile Manufacturing

Machinery 5. Process Plant Machinery 6. Electrical and Power

Machinery 7. Light Engineering

Last reviewed on

Occupation Machining Next review date 24/03/14

Job

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Job Role CNC Setter – Milling

Role Description Setting of computer numerically controlled (CNC) milling machines, in order to perform milling operations on metal components, as per specifications provided.

NVEQF/NVQF level Minimum Educational Qualifications* Maximum Educational Qualifications*

L2

12th Standard

Training (Suggested but not mandatory) TBD

Experience TBD

Applicable National Occupational Standards (NOS)

Compulsory: CSC/ N 0121 Setting of computer numerically controlled (CNC)

milling machines, in order to perform milling operations on metal components.

CSC/ N 0122 Perform milling operations on metal components using computer numerical controlled (CNC) milling machines

CSC/ N 0135 Use basic health and safety practices at the workplace

CSC/ N 0136 Work effectively with others Optional:

1. Nil

Performance Criteria As described in the relevant OS units



Keywords /Terms Description

Core Skills/Generic Skills

Core Skills or Generic Skills are a group of skills that are key to learning and working in today's world. These skills are typically needed in any work environment. In the context of the NOS, these include communication related skills that are applicable to most job roles.

Function Function is an activity necessary for achieving the key purpose of the sector, occupation, or area of work, which can be carried out by a person or a group of persons. Functions are identified through functional analysis and form the basis of NOS.

Job role Job role defines a unique set of functions that together form a unique employment opportunity in an organization.

Knowledge and Understanding

Knowledge and Understanding are statements which together specify the technical, generic, professional and organizational specific knowledge that an individual needs in order to perform to the required standard.

National Occupational Standards (NOS)

NOS are Occupational Standards which apply uniquely in the Indian context

Occupation Occupation is a set of job roles, which perform similar/related set of functions in an industry.

Organisational Context Organisational Context includes the way the organization is structured and how it operates, including the extent of operative knowledge managers have of their relevant areas of responsibility.

Performance Criteria Performance Criteria are statements that together specify the standard of performance required when carrying out a task.

Qualifications Pack(QP) Qualifications Pack comprises the set of NOS, together with the educational, training and other criteria required to perform a job role. A Qualifications Pack is assigned a unique qualification pack code.

Qualifications Pack Code

Qualifications Pack Code is a unique reference code that identifies a qualifications pack.

Scope Scope is the set of statements specifying the range of variables that an individual may have to deal with in carrying out the function which have a critical impact on the quality of performance required.

Sector Sector is a conglomeration of different business operations having similar businesses and interests. It may also be defined as a distinct subset of the economy whose components share similar characteristics and interests.

Sub-Sector Sub-sector is derived from a further breakdown based on the characteristics and interests of its components.

Sub-functions Sub-functions are sub-activities essential to fulfil the achieving the objectives of the function.

Technical Knowledge Technical Knowledge is the specific knowledge needed to accomplish specific designated responsibilities.

Unit Code Unit Code is a unique identifier for a NOS unit, which can be denoted with an ‘N’

Unit Title Unit Title gives a clear overall statement about what the incumbent should be able to do.

Defin

ition

s



Vertical Vertical may exist within a sub-sector representing different domain areas or the client industries served by the industry.

Keywords /Terms Description CNC Computer Numerically Controlled VMC Vertical Machining Center EDM Electro Discharge Machine Ac

rony

ms


CSC/ N 0121 Set computer numerically controlled (CNC) machines for milling

operations on metal components ---------------------------------------------------------------------------------------------------------------------------------------

Overview This unit covers setting of computer numerically controlled (CNC) milling machines, in order to perform milling operations on metal components, as per specifications provided. It does not include machining centres, heavy duty milling, programming or operating of the machine. 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.

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operations on metal components

Unit Code CSC / N 0121

Unit Title (Task) Setup CNC milling machine for operations on metal components

Description This unit covers the skills and knowledge needed to prove the competences required to prepare and set up milling machines (eg. planer/gantry milling machines and boring machines with milling attachments) in accordance with approved procedures. It does not include machining centres, heavy duty milling, programming or operating of the machine. 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. Milling is the machining process of using rotary cutters to remove material from a workpiece feeding in a direction at an angle with the axis of the tool, in order to machine parts to precise sizes and shapes. It covers a wide variety of different operations and machines

This unit involves selecting the appropriate milling cutters, checking them for defects, and mounting and securing them to the relevant tool holding devices and machine spindle.

The candidate 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 their role.

The candidate will be expected to work with a minimum of supervision, taking personal responsibility for their own actions and for the quality of the work that they carry out.

The candidate will have knowledge and understanding of the setting up procedures used, the milling machine used, and its application, and will know about the workholding devices, milling cutters, relevant materials, consumables and setting up procedures, correcting faults and ensuring the work output is to the required specification

The candidate will be required to demonstrate safe working practices throughout, and will understand the responsibility they owe to themselves and others in the workplace.

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Scope This unit/task covers the following: Valid sources for job specifications are:

• job instruction sheet/job card • work drawings and instructions • planning documentation • quality control documents • operation sheets • process specifications • instructions from supervisor

Job specification documents are: • detailed component drawings • approved sketches/illustrations • national, international and organizational standards • reference tables and charts • fabrication/casting drawings • operational diagrams • contractual specifications

Reference charts, tables and graphs pertain to:

• tapping sizes and threads • feeds and speeds • component ratings • machining symbols and tolerances

Job requirements to be established are: • raw materials or components required (type, quality, quantity) • dimensions • limits and tolerances • surface texture requirements • operations required (list, sequence and procedures where applicable) • shape or profiles to be fabricated • projections [orthographic (first angle, third angle)], • isometric (including exploded, oblique) • reference points, lines, edges and surfaces • continuous dimensions • baseline dimensions • workholding devices, instruments and tools to be used • interdependencies • timelines

Preliminary check ensuring readiness of CNC machine for setting includes:

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• machine is clean • correct operating program has been loaded • check that the tool is correct and in a usable condition • check that workholding devices are correct and in usable condition • have received necessary instruction/training on operation of the machine

Milling machines could be:

• boring machines with milling attachments • planer /gantry milling machine

Structural requirements of a range of common machine tools are:

• strength • stability • control of movement • materials (cast iron, cast steel, steel plate) • structures (box column, rib and box bed, fabricated base)/ rigidity

Mounting methods of machine tools are:

• cork pad • adjustable mounting • rag bolt • expanding nut

Alignment in machine tools are:

• slideways: flat, vee, dovetail, cylindrical, comparison of their capabilities, main features, accuracy of movement, means of adjustment, lubrication, protection

• stick-slip: definition, recirculating ball leadscrews, hydrostatic slides typical checks: coaxial alignment between main spindle axis, coaxial alignment between two spindles, alignment of spindle to guideway, squareness of slideways movement, concentricity and end float of spindle, squareness of planes to spindle, setting of guards, stops and automatic safety cut-outs

Methods of alignment are:

• standard tests • straight edge • precision level • autocollimator and reflector • roundness measuring machine • dialing • ball-bar calibration • laser beam

Change speeds methods are:

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• sliding gears • cone pulley • clutch operated • infinitely variable • electrical/electronic

Control feed speeds methods are:

• sliding gears (Norton gearbox) • leadscrew and nut • hydraulic drives • linear scale

Operating principles of computer numerically controlled machine tools

• open loop system • closed loop system • control systems (closed loop servo motors and associated transmission,

stepper motors and associated transmission) • types and function of position transducers (rotary type) • digital control

Part-programme for relative work/tool movement of a CNC machine tool are:

• co-ordinate positioning (absolute, incremental) • use of sub routines • macros and canned cycles • CAD/CAM • CNC program • Post processing • Data transfer

Cutting tools materials are:

• high carbon steel (HCS) • high speed steel (HSS) tungsten carbide • carbide

The factors which will determine selection and use indexible tips are:

• hardness of the material • the cutting characteristics of the material • tolerances to be achieved • component surface finish • component specifications

Coolants and lubricants applicable to machine tool system on the basis of:

• types of coolant pump

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• strainers and filtration methods (including separating tanks and magnetic drum)

• filters • lubrication of headstock/gearbox assemblies of splash and pressurised feed

(lead and feed screws, separation of coolant from lubricants in the lathe cross slides/carriage assemblies)

Equipment used for positioning, aligning and securing the workpiece are :

• clamping direct to machine table • pneumatic or magnetic table • machine vice (such as plain, swivel, universal) • angle plate • vee block and clamps • fixtures • chucks (such as 3, 4 jaw) • indexing head/device • rotary table • magnetic chucks

Types of milling cutters are:

• face mills • slab mills/cylindrical cutters • side and face cutters • slotting cutters • slitting saws • profile cutters • twist drills • boring tools • end mills (HSS and carbide) • Flat end mill • Bullnose end mill • Ball nose • slot drills • straddle milling • gang milling

Characteristics considered for selection of materials for engineering applications are:

• melting points of metals • magnetism • machine ability • application • influence of physical properties of materials on processing techniques(

cutting, forming, joining)

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Set up the machine in accordance with instructions and specifications

• alignment of workholding device • position of cutters in relationship to workpiece/ tool presetter • milling cutter revs per minute • machine guards/safety mechanisms • linear/table feed rate • cutting fluid flow rate • depth of cut for roughing and finishing

Checks to be performed before allowing the machine to operate in full program run mode are:

• after proving the program, measure the dimensions of the component on the machine and correct accordingly

• unload the component after all the dimensions are as per specifications • inspect the component for all dimensions and record findings in specified

formats • make a note of the corrections to be made in the tool wear offsets and correct

accordingly • run the next component • ensure that all dimensions are within specifications • correct if required • repeat this till parts come within specifications without and correction

requirement Checks to be performed before handing over to operator:

• check alignment and levels • check electrical power supplies/insulation, safety switches/devices • check interlocking, security of pipes and couplings • check oil levels • check, oil temperature, oil pressure, cooling/coolant system at light load, • check, oil temperature, oil pressure, cooling/coolant system at full load • check if machine functions as required for production

Set the machine to produce components within all of the following quality and accuracy standards as applicable to the operations performed:

• components to be free from false tool cuts, burrs and sharp edges • dimensional tolerance 20 to 30 microns • flatness & squareness within 0.025mm • surface finish 63μin or 1.6μm • angles within +/- 0.5 degree • bored holes within H6

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Modifying properties are: • effects of cold working • heat treatments (iron-carbon thermal equilibrium diagram) hardening

Corrosion types are:

• pitting • intergranular • galvanic • leaching • oxidation

Setting up the machine to produce internal and external profiles are:

• faces (flat, square, parallel, angular) • steps/shoulders • slots (open ended, enclosed, tee • holes (drilled, bored) • forms (profile -vee, concave, convex, gear forms; indexed or rotated; special) • recesses • serrations

Range of Materials:

• Ferrous metals: eg . carbon steels, stainless steels, cast iron, tool steel, hard metals

• Non-ferrous metals: eg. bronze, bronze alloys, copper and copper alloys Forms of supply are:

• square/rectangular (eg. bar stock, sheet material, machined components) • circular/cylindrical (eg. bar stock, tubes, turned components, flat discs) • irregular shapes/profile (eg. castings, forgings, odd shaped components)

Range statements for numerical and computational ability are:

• degree of accuracy: decimals places, significant figures, fractions as a decimal quantity

• areas of basic shapes: square, rectangle, triangle, circle • compound shapes: involving squares, rectangles, triangles, circles, semi-

circles, quadrants of a circle • surface areas: cube, rectangular prism, cylinder (curved surface area only) • volumes: cube, rectangular prism, cylinder • angles in a triangle: right-angled, isosceles, equilateral • speed and feed parameters

Performance Criteria(PC) w.r.t. the Scope

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Element Performance Criteria Working safely PC1. work safely at all times, complying with health and safety, environmental and

other relevant regulations and guidelines PC2. check that all safety mechanisms are in place and that the equipment is set

correctly for the required operations PC3. adhere to procedures or systems in place for risk assessment, personal

protective equipment and other relevant safety regulations and procedures to realize a safe system of work

PC4. wear the appropriate protective clothing and equipment, and keep the work area clean and tidy

PC5. follow safe practice/approved setting up procedures at all times PC6. ensure that all tools, equipment, power tool cables, extension leads are in a

safe and usable condition PC7. ensure that the components used are free from foreign objects, dirt or other

contamination Prepare for setting CNC milling machine

PC8. obtain job specification from a valid and approved source PC9. read and establish job requirements from the job specification document

accurately PC10. report and rectify incorrect and inconsistent information in job specification

documents as per organization procedures PC11. prepare the work area for the turning operations as per procedure or

operational specification PC12. conduct a preliminary check of the readiness of the CNC milling machine PC13. obtain appropriate cutting tools and hand tools and measuring tools as per

job requirements PC14. ensure that all measuring equipment is calibrated and approved for usage PC15. determine what has to be done and how the machine will be set to achieve

this PC16. extract and use information from engineering drawings and relate

specifications in relation to work undertaken PC17. identify tool requirements from tooling layout and assess their suitability PC18. identify suitable workholding or fixturing device as per the job requirement PC19. ensure that the tools and fixtures are in usable condition(free from breakage,

damage, calibration, etc.) PC20. ensure the correct and latest part-program is uploaded onto the CNC system PC21. pre-set the tooling using setting jigs/fixtures PC22. where appropriate, seek any necessary instruction/training on the operation

of the machine Carry out setting for CNC milling machine

PC23. mount and set the required workholding devices, workpiece and cutting tools PC24. check that the tools have a specific tool number in relation to the operating

program PC25. enter all relevant tool data to the operating program PC26. set tool datums, positions, lengths, offsets and radius compensation

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PC27. mount the work-holding device/fixture onto the machine PC28. set the work-holding device/fixture in relationship to the machine datum’s

and reference points PC29. set the machine tool operating parameters (eg. hydraulic pressure, clamping)

as per the component requirements PC30. place the machine into the correct operating mode, and access the program

edit facility in order to enter tooling data, PC31. conduct trial runs using single block run, dry run and feed and speed override

controls PC32. prove the program tool by tool in single block mode PC33. perform the necessary checks before allowing the machine to operate in full

program run mode PC34. hand-over the machine after set-up to the machine operator along with

relevant instructions and documentation PC35. complete relevant documentation as per organizational procedure PC36. handle the typical problems that can occur with the setting up of the tooling,

work-holding devices and proving the program PC37. switch the CNC milling machine on and off in normal and emergency

situations PC38. return the old cutting tools, workholding device, fixtures, instruments,

drawings and verified tapes and programs back to store, safely and correctly PC39. ensure that there is no damage to the tool/fixture while doing the prove-out PC40. complete documentation during and post operations and submit as per

organizational procedures PC41. deal promptly and effectively with problems within their control, and seek

help and guidance from the relevant people if they have problems that they cannot resolve

PC42. shut down the equipment to a safe condition on conclusion of the activities. PC43. return all tools and equipment to the correct location on completion of the

turning activities PC44. leave the work area in a safe and tidy condition on completion of the fitting

activities Knowledge and Understanding (K)

A. Organizational Context (Knowledge of the company / organization and its processes)

The user/individual on the job needs to know and understand: KB1. legislation, standards, policies, and procedures followed in the company

relevant to own employment and performance conditions KB2. relevant health and safety requirements applicable in the work place KB3. importance of working in clean and safe environment KB4. own job role and responsibilities and sources for information pertaining to

employment terms, entitlements, job role and responsibilities KB5. reporting structure, inter-dependent functions, lines and procedures in the

work area KB6. relevant people and their responsibilities within the work area

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KB7. escalation matrix and procedures for reporting work and employment related issues

KB8. documentation and related procedures applicable in the context of employment and work

KB9. importance and purpose of documentation in context of employment and work

B. Technical Knowledge

The user/individual on the job needs to know and understand: KB10. specific safe working practices, CNC turning procedures and environmental

regulations that must be observed KB11. hazards associated with carrying out the machining operations on a CNC

machine and how can they be minimized KB12. personal protective equipment to be used during the machining activities on

a CNC machine and where can it be obtained KB13. types and sources of appropriate job specifications KB14. common terminology used in CNC milling KB15. how to read and interpret first and third angle component drawings KB16. how to extract information from engineering drawings or data and related

specifications KB17. main features and working parts of the CNC milling machine, and the

accessories that can be used KB18. importance of following specified machining sequences and procedures KB19. importance of ensuring suitability of workpieces/materials and consumables

for the specified job and related procedures KB20. importance and procedures to ensure that tools and equipment are in a safe

and usable condition KB21. various CNC turning operations that can be performed, and the methods and

equipment used KB22. range of workholding methods and devices that are used on CNC lathes KB23. methods of setting the work-holding devices, and the tools and equipment

that can be used KB24. range of cutting tools that are used on CNC milling machines, and typical

applications KB25. various tool holding devices that are used, and the methods of correctly

mounting and securing the cutting tools to the tool holders KB26. basic principles of operation of the various milling machines, and typical

operations that they can perform KB27. how to handle and store milling cutters safely and correctly KB28. how to extract and use information from engineering drawings and related

specifications in relation to work undertaken KB29. how to interpret first and third angle drawings, imperial and metric systems

of measurement, workpiece reference points and system of tolerancing KB30. terminology used in milling in relation to the activities undertaken KB31. range of workholding methods and devices that are used on machines

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KB32. methods of mounting and setting the workpiece in/on the workholding devices, and the tools and equipment that can be used

KB33. different types of milling cutters that are used, and how they are selected, prepared and mounted to the machine tool holding devices

KB34. factors which determine speeds and feeds to be used KB35. how the various types of material will affect the feeds and speeds that can be

used KB36. types of cutting fluid that are used, and precautions to be taken when

handling and using them KB37. advantages of using pre-set tooling, and how to set the tooling using setting

jigs/fixtures KB38. use of tool posts, magazines and carousels, and how to position and identify

the tools in relationship to the operating program KB39. types and function of error messages and appropriate, corresponding

subsequent action KB40. importance of proving the program and how to do it KB41. quality control procedures that are used, inspection checks to be carried out,

and the equipment that will need to be used KB42. how to check the quality of the shaped components against the required

quality standards KB43. importance of reporting problems in a timely manner KB44. report conditions and seek appropriate assistance in a timely manner to

address risk of failure to comply with necessary targets and specifications KB45. deal with finished components as per organizational guidelines KB46. complete documentation during and post operations as per organizational

procedures KB47. return all tools and equipment to the correct location on completion of the

fitting activities KB48. leave the work area in a safe and tidy condition on completion of job activities KB49. range of materials used in common engineering applications KB50. forms of supply of materials KB51. identify materials by their physical properties

Skills (S) [Optional]

A. Core Skills/ Generic Skills

Communication

The user/ individual on the job needs to know and understand how to: SA1. read and interpret information correctly from various job specification

documents, manuals, health and safety instructions, memos, etc. applicable to the job in English and/or local language

SA2. fill up appropriate technical forms, process charts, activity logs as per organizational format in English and/or local language

SA3. convey and share technical information clearly using appropriate language SA4. check and clarify task-related information SA1. liaise with appropriate authorities using correct protocol SA5. communicate with people in respectful form and manner in line with

organizational protocol SA6. recognize and use common CNC terminology

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Numerical and computational skills

SA7. identify problems with work planning, procedures, output and behavior and their implications

SA8. prioritize and plan for problem solving SA9. communicate problems appropriately to others SA10. identify sources of information and support for problem solving SA11. seek assistance and support from other sources to solve problems SA12. identify effective resolution techniques SA13. select and apply resolution techniques SA14. seek evidence for problem resolution

Learning

The user/individual on the job needs to know and understand how to: SA1. maintain current knowledge of applicable standards, legislation, codes of

practice and product/process developments SA2. participate in on-the-job and other learning, training and development

interventions and assessment SA3. clarify task related information with appropriate personnel or technical

adviser SA4. seek to improve and modify own work practices

B. Professional Skills

Problem Solving

The user/individual on the job needs to know and understand how to: SB1. identify problems with work planning, procedures, output and behavior and

their implications SB2. prioritize and plan for problem solving SB3. communicate problems appropriately to others SB4. identify sources of information and support for problem solving SB5. seek assistance and support from other sources to solve problems SB6. identify effective resolution techniques SB7. select and apply resolution techniques SB8. seek evidence for problem resolution

Plan and Organize

The user/individual on the job needs to know and understand: SB1. plan, prioritize and sequence work operations as per job requirements SB2. organize and analyze information relevant to work SB3. basic concepts of shop-floor work productivity including waste reduction,

efficient material usage and optimization of time Initiative and Enterprise

The user/individual on the job needs to know and understand how to: SB4. importance and impact of initiative and enterprise for achieving better results

for self, others and organization SB5. how to undertake and express new ideas and initiatives to others SB6. modify work plan to overcome unforeseen difficulties or developments that

occur as work progresses

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SB7. participate in improvement procedures including process, quality and internal/external customer/supplier relationships

SB8. one’s competencies can and should be applied in new and different situations and contexts to achieve more

Self-Management

The user/individual on the job needs to know and understand how to: SB9. importance of taking responsibility for own work outcomes SB10. importance of adherence to work timings, dress code and other organizational

policies SB11. importance of following laid down rules, procedures, instructions and policies SB12. importance of exercising restraint while expressing dissent and during conflict

situations SB13. how to avoid and manage distractions to be disciplined at work SB14. importance of time management for achieving better results

Team Work

The user/individual on the job needs to know and understand how to: SB15. work in a team in order to achieve better results SB16. identify and clarify work roles within a team SB17. communicate and cooperate with others in the team SB18. seek assistance from fellow team members

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NOS Version Control

NOS Code CSC / N 0121


Industry Capital Goods Drafted on 14/03/14

Industry Sub-sector

1. Machine Tools 2. Tools Dies And Press

Tools 3. Plastic Manufacturing


Machinery 5. Process Plant

Machinery 6. Electrical and Power


Last reviewed on

Next review date 24/03/14

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CSC/ N 0122 Perform milling operations on metal components using computer

numerical controlled (CNC) milling machines ---------------------------------------------------------------------------------------------------------------------------------------

Overview This unit covers the skills and knowledge required to operate a computer numerical control (CNC) milling machine on a range of metals and metal components to modify features to achieve a range of specifications.

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numerical controlled (CNC) milling machines

Unit Code CSC/ N 0122 Unit Title (Task)

Perform milling operations on metal components using computer numerically controlled(CNC) milling machines

Description This unit covers the skills and knowledge needed operate milling machines (eg. planer/gantry milling machines and boring machines with milling attachments) in accordance with approved procedures. It does not include machining centres, heavy duty milling, programming or setting of the machine. Milling is the machining process of using rotary cutters to remove material from a workpiece feeding in a direction at an angle with the axis of the tool, in order to machine parts to precise sizes and shapes. It covers a wide variety of different operations and machines

This unit involves performing a broad range of milling operations on metal components using computer numerically controlled (CNC) milling machines. The candidate will be expected to produce components that combine a number of different features and to achieve production targets.

The candidate 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 their role.

The candidate will be expected to work under supervision, taking personal responsibility for their own actions and for the quality of the work that they carry out.

The candidate will have knowledge and understanding of the setting up procedures used, the milling machine used, and its application, and will know about the workholding devices, milling cutters, relevant materials, consumables and setting up procedures, correcting faults and ensuring the work output is to the required specification

The candidate will be required to demonstrate safe working practices throughout, and will understand the responsibility they owe to themselves and others in the workplace.

Scope Types of component material for machining are: • ferrous metals: carbon steels (low, medium, high), stainless steels (austenitic,

ferritic, martensitic), cast iron • non-ferrous metals: aluminium and aluminium alloys, copper and copper alloys

(brass, bronze) • ciba/wood

Engineering information sources are: • standards • instruction manuals • technical handbooks • tables

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• charts (including: flow, Gantt, tally) • graphs (including histograms, scatter diagrams) • data sheets • text books and reference materials • computer applications

Abbreviations and notations : • symbols and abbreviations for engineering drawings pertaining to machining

Application of reference charts, tables, graphs and standards pertain to: • tapping sizes and threads • feeds and speeds • component ratings • welding symbols • machining symbols and tolerances

Drawings, dimensioning and labeling pertain to: • projections (orthographic [first angle, third angle], isometric [including

exploded], oblique) • reference points, lines, edges and surfaces, continuous dimensions, baseline

dimensions

Forms of supply are: • bar (flat, round, square, hexagonal) • plate • sheet • coated sheet (tin plate, galvanised, plasticized) • pipe and tube • castings • forgings • extrusions

Types of milling cutters to be mounted on appropriate tool holding device are: • face mills • end mills • twist/core drills • boring tools • reamers • slot drills • special profile cutters

Features of machined components produced with combine various operations are:

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• flat faces • steps/shoulders • open ended slots • enclosed slots/recesses • drilled holes linearly pitched • parallel faces • square faces • angular faces • internal profiles • external profiles • drilled holes on pitched circles • bored holes • reamed holes • tapped holes • circular/curved profiles • special forms (such as concave, convex)

Checks for accuracy are: • linear dimensions (such as lengths, depths) • slots (such as position, width, depth) • flatness • surface finish • squareness • parallelism • hole size/fit • angles • recesses • thread fit

Measuring equipment are: • external micrometers • vernier/digital/dial calipers • dial test indicators (DTI) • plunger dial • linear dial • surface finish equipment (such as comparison plates, machines) • rules • internal micrometers • depth micrometers • depth Verniers • slip gauges • bore/hole gauges

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• thread gauges • plug gauges • radius/profile gauges • vernier protractors

Produce components within all of the following standards, as applicable to the

process: • components to be free from false tool cuts, burrs and sharp edges • dimensional tolerance 20 to 30 microns • there must be one or more specific dimensional tolerances within +/- 0.1mm or

+/- 0.004” • surface finish 63 μin or 1.6μm • reamed holes within H6 • screw threads medium fit • angles/tapers within +/- 0.5 degree • flatness and squareness 0.025mm

Hazards associated with the use CNC milling machines are: • automatic machine operations • revolving/moving parts of machinery • airborne and hot metal particles • sharp cutting tools • lifting and handling workholding devices • burrs and sharp edges on component • short circuits

The safe working practices and procedures to be followed when preparing and using CNC milling machines • ensuring the correct isolation of the machine before mounting workholding

devices and tooling • closing the door before machining starts • fitting and adjusting machine guards • ensuring that the workpiece is secure and that tooling is free from workpiece

before starting the machine • the personal protective equipment (PPE) to be worn for the CNC milling activities • as correctly fitting overalls and safety glasses • ensuring that, if they have long hair, it is tied back or netted • removing any jewellery or other items that can become entangled in the

machinery The safety mechanisms on the machine are: • emergency stop buttons • emergency brakes

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The various hand and automatic modes of machine control are: • program operating and • control buttons • keyboard • touchpads

The computer coding language used in CNC programs are: • machine axes • positional information • machine management • auxiliary functions • CAM

Modifying properties of materials are: • effects of cold working • heat treatment (annealing, normalizing, hardening, tempering)

The factors which will determine selection and use of tungsten carbide, ceramic and diamond indexible tips are: • hardness of the material • the cutting characteristics of the material • tolerances to be achieved • component surface finish • component specifications

Access to the program edit facility in order to enter tooling data are: • tool datums • positions • lengths • offsets compensation • radius compensation

Conduct trial runs as: • single block run • dry run • feed and speed override controls

Factors that affect the feeds and speeds are: • type and condition of material • workholding method • tooling used

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• tolerance to be achieved • finish to be achieved

The activities for keeping the work area and machine in a safe condition (5S) are: • correctly isolated • operating programs closed or removed • cleaning the machine • ensuring that any spilt cutting fluids are correctly dealt with • disposing of waste

Methods of rotational movement are: • belt drives (flat, vee and tooth) • gears • hydraulic actuators

Methods of linear movement are: • screw and nut (vee, square [including multi-start] • relationship between the lead of a screw and the motion transmitted • engaging screw drives [fixed nuts, split nuts]) • rack and pinion • recirculating ball-screw • crank and connecting rod • cams (lift, dwell and types of motion produced) hydraulic actuator • magnetic movement • ball bearing

Physical properties of materials are: • melting points of metals • density • colour • magnetism • corrosion resistance • conductivity • insulation

Methods to change speeds are: • sliding gears/knobs • cone pulleys • clutch operated • infinitely variable • electrical/electronic

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Methods to control feed speeds are: • sliding gears (Norton gearbox) • leadscrew and nut • hydraulic drives

Mechanical properties of materials are: • tensile strength • toughness • hardness • elasticity • ductility • malleability

Job requirement to be established are: • material being cut • RPM/feed rate • type of tool • type of cooling /lubrication • depth of cut • trigonometry • dimensions • tolerances • operations required • sequence and procedure

Application of analytical methods to engineering mathematical calculations are: • degree of accuracy: decimals places, significant figures, fractions as a decimal

quantity • areas of basic shapes: square, rectangle, triangle, circle • compound shapes: involving squares, rectangles, triangles, circles, semi-circles,

quadrants of a circle • surface areas: cube, rectangular prism, cylinder (curved surface area only) • volumes: cube, rectangular prism, cylinder • angles in a triangle: right-angled, isosceles, equilateral

Application of analytical methods to engineering science calculations are: • force: definition, solve problems using formulae • work done: definition, solve problems using formulae • power: mechanical power, electrical power • energy: mechanical energy, electrical energy • efficiency: mechanical (power, energy), electrical (power, energy) • moment of a force: levers, torque

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• relative density: relative to water • strength of engineering materials: yield stress, tensile stress, percentage

elongation, force/extension graph, stress/strain graph

Performance Criteria(PC) w.r.t. the Scope

Element Performance Criteria Working safely PC1. adhere to procedures or systems in place for risk assessment, personal

protective equipment (PPE) and other relevant safety regulations PC2. ensure machine guards are in place and correctly adjusted PC3. ensure components are held securely (without damage or distortion) PC4. ensure cutting tools are maintained in a suitable/safe condition PC5. ensure the work area is maintained and left in a safe and tidy condition PC6. check that all safety mechanisms are in place PC7. tool change positions are safe and clear of the workpiece and machine

equipment Prepare for CNC machining activities

PC8. load/input the program to the machine controller accurately PC9. check the program for errors using the approved procedures PC10. mount and set the required workholding devices, workpiece and cutting tools

correctly and securely PC11. securing tools to the machine spindle or positioning tools in the correct

position in the tool magazine/carousel PC12. set equipment correctly for the required operations PC13. securing tools to the machine spindle or positioning tools in the correct

position in the tool magazine/carousel PC14. checking that tools have the correct specific tool number in relation to the

operating program PC15. entering all relevant tool data to the operating program (such as tool lengths,

tool offsets, radius compensation) PC16. pre-setting tooling using setting jigs/fixtures (where appropriate) PC17. setting tool datum for each axis based as per operational requirement

(equipment and tools used) PC18. saving changes to the program after changes are made

Perform the CNC milling operations

PC19. prepare the tooling for operation applicable to the machine type PC20. run the operating program PC21. check and adjust the machine tool speeds, feeds and operating parameters to

achieve the component specification PC22. confirm that the machine and program operates safely and correctly PC23. produce machined components that combine different operations and have

features that cover all applicable PC24. deal promptly and effectively with problems within their control, and seek

help and guidance from the relevant people if they have problems that they cannot resolve

PC25. shut down the equipment to a safe condition on completion of the machining activities

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Measure and checking for quality

PC26. carry out the necessary checks for accuracy PC27. use correct measuring equipment during the machining and checking

activities PC28. produce components to all of the quality and accuracy standards, as per

specification and as applicable to the operation PC29. check all operations are carried out to the program co-ordinates PC30. check the correct tools are selected at the appropriate points in the program PC31. check tool offsets are entered correctly into the machine controller PC32. ensure tool cutter paths are executed safely and correctly PC33. check auxiliary functions operate at the correct point in the program (such as

cutter start/stop, coolant flow) PC34. check programs have been saved in the appropriate format

Knowledge and Understanding (K) B. Technical Knowledge

The user/individual on the job needs to know and understand KB1. safe working practices and procedures to be followed when preparing and

using CNC milling machines KB2. hazards associated with the using CNC milling machines and how they can be

minimized KB3. personal protective equipment (PPE) to be worn for the CNC milling activities KB4. safety mechanisms on the machine KB5. correct operation of the various manual and automatic modes of machine

control KB6. how to stop the machine in both normal and emergency situations, and the

procedure for restarting after an emergency KB7. how to use and extract information from engineering drawings or data and

related specifications KB8. how to interpret first and third angle drawings, imperial and metric systems

of measurement, absolute and incremental systems, workpiece zero/reference points and system of tolerancing

KB9. computer coding language used in CNC programs KB10. how to set the machine controller in the program and editing mode, and how

to enter or download the prepared program KB11. how to deal with error messages and faults on the program or equipment KB12. range of workholding methods and devices that are used on CNC milling

machines KB13. why it is important to set the workholding device in relationship to the

machine axis and reference points KB14. methods of setting the workholding devices, and the tools and equipment

that can be used KB15. range of milling cutters/cutting tools that are used on CNC milling machines,

and their typical applications KB16. how to check that the cutting tools are in a safe and serviceable condition KB17. use of tungsten carbide, ceramic and diamond indexible tips, and the factors

which will determine their selection and use

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KB18. advantages of using pre-set tooling, and how to set the tooling by using setting jigs/fixtures

KB19. use of tool magazines and carousels, and how to position and identify the tools in relationship to the operating program

KB20. how to place the machine into the correct operating mode, and how to access the program edit facility in order to enter tooling data

KB21. importance and procedures to conduct trial runs KB22. items that they need to check before allowing the machine to operate in full

program run mode KB23. factors that affect the feeds and speeds that can be used, and why these may

need to be adjusted from the program setting KB24. application of cutting fluids with regard to a range of different materials, and

why some materials do not require the use of cutting fluids KB25. how to save the completed programs in the appropriate format, and the

importance of storing programs and storage devices safely and correctly, away from contaminants and possible corruption

KB26. typical problems that can occur with the CNC milling activities, and what to do if they occur

KB27. span and scope of authority when dealing with problems and avenues of support and escalation

KB28. importance of leaving the work area and machine in a safe condition on completion of the activities

KB29. how to apply analytical methods to engineering mathematical applications KB30. basic knowledge of metallurgy

Skills (S) [Optional]

A. Core Skills/ Generic Skills

Communication

The user/ individual on the job needs to know and understand how to: SA1. read and interpret information correctly from various job specification

documents, manuals, health and safety instructions, memos, etc. applicable to the job in English and/or local language

SA2. fill up appropriate technical forms, process charts, activity logs as per organizational format in English and/or local language

SA3. convey and share technical information clearly using appropriate language SA4. check and clarify task-related information SA5. liaise with appropriate authorities using correct protocol SA6. communicate with people in respectful form and manner in line with

organizational protocol Numerical and computational skills

The user/ individual on the job needs to know and understand how to: SA7. undertake numerical operations, and calculations/ formulae SA8. identify and draw various basic, compound and solid shapes as per

dimensions given SA9. use appropriate measuring techniques and units of measurement SA10. use appropriate units and number systems to express degree of accuracy SA11. interpret and express tolerance in terms of limits on dimensions SA12. calculation of the value of angles in a triangle

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Learning

The user/individual on the job needs to know and understand how to: SA13. assess and modify own work practices SA14. use manuals, online help and other reference materials such as

catalogues/lists as required SA15. maintain current knowledge of applicable standards, legislation, codes of

practice and product/process developments SA16. participate in on the job and other training interventions and assessment SA17. clarify task related information with appropriate personnel or technical

adviser B. Professional Skills

Problem Solving

The user/individual on the job needs to know and understand how to: SB1. identify problems with work planning, procedures, output and behavior and

their implications SB2. prioritize and plan for problem solving SB3. communicate problems appropriately to others SB4. identify sources of information and support for problem solving SB5. seek assistance and support from other sources to solve problems SB6. identify effective resolution techniques SB7. select and apply resolution techniques SB8. seek evidence for problem resolution

Plan and Organize

The user/individual on the job needs to know and understand: SB9. plan, prioritize and sequence work operations as per job requirements SB10. organize and analyze information relevant to work SB11. basic concepts of shop-floor work productivity including waste reduction,

efficient material usage and optimization of time

Initiative and Enterprise

The user/individual on the job needs to know and understand how to: SB12. importance and impact of initiative and enterprise for achieving better results

for self, others and organization SB13. how to undertake and express new ideas and initiatives to others SB14. modify work plan to overcome unforeseen difficulties or developments that

occur as work progresses SB15. participate in improvement procedures including process, quality and

internal/external customer/supplier relationships SB16. one’s competencies can and should be applied in new and different situations

and contexts to achieve more Self-Management

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The user/individual on the job needs to know and understand: SB17. importance of taking responsibility for own work outcomes SB18. importance of adherence to work timings, dress code and other

organizational policies SB19. importance of following laid down rules, procedures, instructions and policies SB20. importance of exercising restraint while expressing dissent and during conflict

situations SB21. how to avoid and manage distractions to be disciplined at work SB22. importance of time management for achieving better results

Team Work

The user/individual on the job needs to know and understand how to: SB23. work in a team in order to achieve better results SB24. identify and clarify work roles within a team SB25. communicate and cooperate with others in the team SB26. seek assistance from fellow team members

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NOS Version Control

NOS Code CSC/ N 0122


Industry Capital Goods Drafted on 14/03/14

Industry Sub-sector

1. Machine Tools 2. Tools Dies And Press

Tools 3. Plastic Manufacturing


Machinery 5. Process Plant

Machinery 6. Electrical and Power


Last reviewed on

Next review date 14/03/14

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