Block B – Machine-tool Setup and Operation

Context

Tool and die makers determine the sequence of machining operations and equipment required to produce the end product in the most efficient manner. To do so, they use various techniques and machine-tools such as conventional drills, lathes, milling machines, grinders and saws, and computer numerical control (CNC) machines and Electrical Discharge Machines (EDM).

Trends

The continued increase in the use of CNC machines and new machining processes such as water jet cutting, laser cutting, high speed machining and 3D printing are influencing the tool and die industry by making the machining process more efficient and cost effective.

The effect on tool and die makers is less direct involvement in the machining of production tool components. This means tool and die maker skills are focussed more on planning, costing, final fitting, assembly, try-outs, development and proving out of tooling.

Related Components

Not applicable.

Tools and Equipment

See Appendix A.

Task 5 Plans and prepares for machine-tool operations.

Required Knowledge

• K 1 machine operations and sequencing
• K 2 machine capacity and capabilities
• K 3 types of machine-tools such as lathes, drills, grinders, saws and milling machines
• K 4 work holding devices and equipment
• K 5 machining accessories
• K 6 limits and capabilities of tooling, accessories and holding devices
• K 7 fragile items such as thin wall components and tool sensors
• K 8 clamping pressures and alignment
• K 9 types of tooling such as high speed steel (HSS), diamond and ceramic inserts, carbide tooling and carbide inserts
• K 10 installation and positioning techniques of types of tool holders
• K 11 machine capabilities such as speeds and feeds
• K 12 tool geometry such as rake angles, relief angles and chip breakers
• K 13 thread types such as Unified National Fine (UNF), Unified National Coarse (UNC), Acme, National Pipe Taper (NPT), National Pipe Straight (NPS) and metric
• K 14 types of alignment equipment such as dial indicator, precision level and square
• K 15 calibration equipment and procedures

Sub-task - B-5.01 Plans machining sequence.

Key Competencies

• B-5.01.01 review drawings and sketches pertaining to current task to ensure accuracy of procedure, finishes and machining allowances
• B-5.01.02 determine type of equipment such as mills, lathes, grinders, drill presses and power saws
• B-5.01.03 establish the sequence of machining operations
• B-5.01.04 match accessories and work holding devices to workpiece requirements
• B-5.01.05 select cutting tool such as HSS, diamond and ceramic inserts, carbide tooling and inserts according to material type and machining requirements

Sub-task - B-5.02 Establishes workpiece datum.

Key Competencies

• B-5.02.01 verify location of work datum by referring to drawings and sketches
• B-5.02.02 select alignment instruments such as probes, edge finders and dial indicators
• B-5.02.03 touch off designated datum surfaces of workpieces using tools such as probes and edge finders

Sub-task - B-5.03 Sets up work holding devices in machine-tools.

Key Competencies

• B-5.03.01 select machine-tool work holding devices such as vises, V-blocks, drive plates, angle plates, chucks, collets, steady rests, face plates and magnetic chucks
• B-5.03.02 position, align and secure work holding device to match workpiece requirements
• B-5.03.03 apply clamping forces according to characteristics of part and cutting forces

Sub-task - B-5.04 Sets up machine tooling and accessories.

Key Competencies

• B-5.04.01 install and mount tooling and inserts in tool holders
• B-5.04.02 mount tool holder in machines
• B-5.04.03 position and align accessories using tools such as dial indicators, gauge blocks and squares
• B-5.04.04 join band saw blades
• B-5.04.05 perform calculations such as taper and parallelism correction
• B-5.04.06 perform presetting of machine cutting tools
• B-5.04.07 adjust, position and secure drill press accessories such as jigs, fixtures and work holding devices
• B-5.04.08 adjust, position and secure lathe accessories such as taper attachments, steady rests and follower rests
• B-5.04.09 adjust, position and secure milling accessories such as rotary tables, vises, universal dividing heads and boring heads B-5.04.10 adjust, position and secure grinding accessories such as angle plates, collets, steady rests, chucks, drive dogs and mandrels.

Sub-task - B-5.05 Sets up workpiece in machine-tool.

Key Competencies

• B-5.05.01 orientate workpiece in the work holding device
• B-5.05.02 fasten and secure workpiece into work holding devices such as collets, chucks, V-blocks, angle plates and vises

Sub-task - B-5.06 Selects speeds and feeds of machine-tools.

Key Competencies

• B-5.06.01 determine rigidity of machine tool, workpiece and setup
• B-5.06.02 calculate speeds and feeds according to machining requirements

Task 6 Operates conventional drill presses, lathes and milling machines.

Required Knowledge

• K 1 drilling techniques such as pecking, centre drilling and deep hole drilling
• K 2 work holding size and types for selected operation
• K 3 counterbore diameter and corresponding pilot diameter
• K 4 required surface finish
• K 5 tap types such as spiral flute, spiral point and form taps
• K 6 thread types such as UNF, UNC, Acme, NPT, NPS and metric
• K 7 cutting tool geometry
• K 8 types of tools and tool holders
• K 9 types of parting and turning tools such as carbide and HSS
• K 10 hole finishing techniques such as drilling, reaming, boring and honing
• K 11 grooving tool materials such as carbide and HSS
• K 12 procedures and techniques to produce internal and external threads
• K 13 single and multi-start threads
• K 14 methods of milling such as climb milling and conventional milling
• K 15 horizontal and vertical milling
• K 16 types and applications of specialized cutters
• K 17 procedures for cutting pockets, profiles and keyways
• K 18 procedures for turning tapers such as using taper turning attachments, compound rests and tail stock offsets
• K 19 procedures for knurling, parting, grooving and contouring

Sub-task - B-6.01 Performs hole making and finishing operations.

Key Competencies

• B-6.01.01 read documentation to determine operations to be performed
• B-6.01.02 assess hole requirements to determine tooling such as countersinks, counterbores, chamfering tools, spot faces, centre drills, spot drills, pilot drills, drills and boring heads
• B-6.01.03 select and set up tooling such as drills, reamers, boring bars, countersinks and spot faces according to operation
• B-6.01.04 perform visual inspection of tool for wear and damage
• B-6.01.05 install drill chuck into tail stock, drill press and milling machine
• B-6.01.06 mount drill for application
• B-6.01.07 set up and secure workpiece
• B-6.01.08 touch off drill to workpiece surface to establish a reference point
• B-6.01.09 pre-drill workpiece using tooling such as centre drills and pilot drills
• B-6.01.10 feed drill into workpiece to produce hole
• B-6.01.11 apply cutting fluids for lubrication, cooling and chip removal
• B-6.01.12 apply tapping procedures according to machine-tool type
• B-6.01.13 identify process problems such as drill wandering, oversized holes, misalignment of tail stock/turret, incorrect speeds and feeds, wrong depth of cut, incorrect cutter geometry, tool wear, insufficient coolant, chip removal and damage to cutting tool
• B-6.01.14 measure and check hole throughout the process to make adjustments
• B-6.01.15 finish hole and hole features using tooling such as drills, reamers, boring bars, boring heads, taps and tapping heads according to requirements
• B-6.01.16 verify holes and hole features meet specifications using inspection equipment such as telescopic gauges, optical comparators, small hole gauges, pin gauges, go no-go gauges, thread gauges, dial indicators and vernier calipers

Sub-task - B-6.02 Turns surfaces using lathe.

Key Competencies

• B-6.02.01 read documentation to determine operations to be performed
• B-6.02.02 perform visual inspection of tool for wear and damage
• B-6.02.03 position and secure workpiece using work holding devices such as chucks, collets and steady rests
• B-6.02.04 touch off tool on workpiece to establish primary reference
• B-6.02.05 turn internal and external surfaces
• B-6.02.06 set compound rest, taper attachment or tail stock offset to required angle
• B-6.02.07 rough-turn to remove material and to prepare for finishing operation
• B-6.02.08 produce contours using tools such as templates and form tools
• B-6.02.09 measure workpiece throughout the process to make adjustments
• B-6.02.10 identify process problems such as chatter, tool deflection, taper and run-out
• B-6.02.11 finish-turn to comply with specifications
• B-6.02.12 verify workpiece meets specifications using inspection equipment such as micrometers, depth micrometers, dial indicators, templates and vernier calipers

Sub-task - B-6.03 Faces surfaces using milling machine.

Key Competencies

• B-6.03.01 read documentation to determine operations to be performed
• B-6.03.02 perform visual inspection of tool for wear and damage
• B-6.03.03 position and secure workpiece using work holding devices such as chucks, collets, vises, angle plates and sine plates
• B-6.03.04 machine vertical, horizontal and angled surfaces
• B-6.03.05 touch off tool on workpiece to establish primary reference points (datum)
• B-6.03.06 measure workpiece to determine amount of excess material using inspection equipment such as depth micrometers, gauge blocks and dial indicators
• B-6.03.07 remove required amounts of excess material to meet specifications
• B-6.03.08 measure workpiece throughout the process and make required adjustments
• B-6.03.09 identify process problems such as incorrect speeds and feeds, wrong depth of cut, incorrect cutter geometry, insufficient coolant, chatter, tool wear and incorrect tool height setting
• B-6.03.10 finish-face to comply with specifications
• B-6.03.11 verify workpiece meets specifications using inspection equipment such as gauge blocks, micrometers, vernier calipers, straight edges, squares, surface finish comparators and dial indicators

Sub-task - B-6.04 Performs parting, grooving and knurling using lathe.

Key Competencies

• B-6.04.01 read documentation to determine operations to be performed
• B-6.04.02 select tools such as parting and grooving tools
• B-6.04.03 select knurling wheels for pattern and size
• B-6.04.04 perform visual inspection of tool for wear and damage
• B-6.04.05 measure tool location from reference point
• B-6.04.06 set up and position workpiece for grooving internal and external surfaces
• B-6.04.07 touch off tool on workpiece to establish primary reference points (datum)
• B-6.04.08 apply cutting fluids for lubrication, cooling and chip removal
• B-6.04.09 apply knurling procedures
• B-6.04.10 visually inspect workpiece throughout the process
• B-6.04.11 identify process problems such as tool wear, incorrect speeds and feeds, depth of cut, cutter geometry, insufficient coolant, chattering, galling, flaking, tool wandering and chip removal
• B-6.04.12 measure roughed-out workpiece to make finish adjustments
• B-6.04.13 finish the workpiece to comply with specifications
• B-6.04.14 verify workpiece meets specifications using inspection equipment such as micrometers, gauge blocks, vernier calipers, straight edges and sample piece
• B-6.04.15 ensure parted workpiece is retained without damage to workpiece or equipment

Sub-task - B-6.05 Cuts internal and external threads using lathe.

Key Competencies

• B-6.05.01 read documentation to determine operations to be performed
• B-6.05.02 perform visual inspection of tool for wear and damage
• B-6.05.03 set up machine to cut external or internal threads
• B-6.05.04 set up lathe to cut internal or external multi-start threads
• B-6.05.05 adjust gear box for required thread pitch
• B-6.05.06 set up compound rest to required angle
• B-6.05.07 grind cutting tools to produce thread form
• B-6.05.08 use center gauge to establish required angle on tool
• B-6.05.09 touch off tool on workpiece to establish primary reference (datum)
• B-6.05.10 produce threads using accessories such as die heads, tapping heads and taper attachments
• B-6.05.11 verify thread pitch
• B-6.05.12 cut thread to required specifications
• B-6.05.13 measure thread pitch diameter using thread wires
• B-6.05.14 identify process problems such as chatter, tool deflection and taper
• B-6.05.15 deburr threaded workpiece to remove sharp edges
• B-6.05.16 verify final workpiece dimensions using inspection equipment such as thread wires, thread micrometers, go no-go gauges, sample pieces and optical comparator (shadow graph)

Sub-task - B-6.06 Performs profiling, pocketing and slotting using milling machine.

Key Competencies

• B-6.06.01 read documentation to determine operations to be performed
• B-6.06.02 perform visual inspection of tool for wear and damage
• B-6.06.03 position and secure workpiece in work holding device
• B-6.06.04 perform profile calculations
• B-6.06.05 use edge finder or dial indicator to locate datum surface
• B-6.06.06 touch off milling cutter to workpiece surface to establish a reference point
• B-6.06.07 cut profiles using accessories such as rotary tables and indexing heads
• B-6.06.08 apply cutting fluids to remove chips and to cool workpiece and tools
• B-6.06.09 rough out workpiece using tooling such as indexable carbide cutters, roughing end mills and radius cutters
• B-6.06.10 identify process problems such as incorrect speeds and feeds, incorrect depth of cut, incorrect cutter geometry, tool wear, insufficient coolant and chip removal
• B-6.06.11 measure roughed-out workpiece to make finish adjustments
• B-6.06.12 finish workpiece using tooling such as carbide end mills, dovetail cutters, woodruff cutters, radius cutters and T-slot cutters
• B-6.06.13 verify workpiece meets specifications using inspection equipment such as gauge blocks, radius gauges, micrometers, vernier calipers and dial indicators

Task 7 Operates power saws.

Required Knowledge

• K 1 types and capabilities of power saws such as vertical, horizontal, reciprocating and circular
• K 2 capacity of saw such as speed, feed and size
• K 3 work holding and supporting devices such as infeed support and outfeed support
• K 4 blade sizes, set, tooth pitch and composition
• K 5 types of blade guides such as carbide, roller and bearing
• K 6 blade effect on cutting rate, tool life, finish and accuracy
• K 7 break-in period of new blades
• K 8 blade installation techniques and procedures for various saw types
• K 9 workpiece characteristics such as shape, material and size
• K 10 clamping pressures
• K 11 saw features such as manual stops, automatic indexing devices and computer numerical control (CNC) devices
• K 12 types of power saw accessories such as nesting fixtures, fences, gravity feed and vises
• K 13 band saw blade welding procedures such as butt welding and silver soldering

Sub-task - B-7.01 Saws straight and angle cuts.

Key Competencies

• B-7.01.01 select saw blades and tooth pitch according to material type and thickness
• B-7.01.02 apply cutting fluid to remove chips and to cool saw blade
• B-7.01.03 guide workpiece into vertical band saw blade using a pusher guide (push stick) with consistent cutting pressure to protect blade and provide an efficient cut
• B-7.01.04 adjust angle of vise on horizontal saw according to required angle of cut
• B-7.01.05 monitor straightness of cut during cutting process
• B-7.01.06 square off end of material (reference cut) to ensure an accurate measurement
• B-7.01.07 identify process problems such as incorrect speeds and feeds, and binding or overheating blade
• B-7.01.08 verify workpiece meets specifications using inspection equipment such as protractors, tape measures and machinist square

Sub-task - B-7.02 Cuts irregular shapes.

Key Competencies

• B-7.02.01 select saw blade width, pitch and kerf according to required profile (contour)
• B-7.02.02 feed material and follow contour layout line
• B-7.02.03 apply cutting fluid to remove chips and to cool saw blade
• B-7.02.04 guide workpiece into vertical band saw blade using a pusher guide (push stick) with consistent cutting pressure to protect blade and provide an efficient cut
• B-7.02.05 monitor angle of cut during cutting process
• B-7.02.06 identify process problems such as incorrect speeds, feeds, and binding or overheating blade
• B-7.02.07 verify workpiece meets specifications using inspection equipment such as templates and radius gauges

Task 8 Operates grinders.

Required Knowledge

• K 1 types of grinding machines such as surface, cylindrical, and tool and cutter
• K 2 capacity of grinding machine
• K 3 grinding machine accessories such as support rests and power heads
• K 4 types, sizes and grades of grinding wheels such as cubic boron nitride (CBN), aluminium oxide and silicon carbide
• K 5 grinding machine operations such as surface, cylindrical, and tool and cutter
• K 6 sequence of grinding machine operations
• K 7 types of work holding devices such as centres, four-jaw chucks, three-jaw chucks, face plates, fixtures, magnetic chucks and magnetic sub-plates
• K 8 clamping pressure
• K 9 capacity of work holding device
• K 10 techniques and procedures for storing, handling and mounting grinding wheels
• K 11 blotter (paper washer) applications
• K 12 balancing techniques and procedures
• K 13 truing and dressing techniques and procedures such as contour dressing and diamond dressing
• K 14 types of accessories such as rests, internal grinding head, wheel dressers, laminated blocks, magnetic spring clamps, chucks, drive dogs and mandrels
• K 15 contact material for steady rests and follower rests such as bronze pads, polymer pads and brass pads
• K 16 workpiece characteristics such as shape, material and size
• K 17 setup and alignment techniques such as shimming, dialling-in and using sine bars
• K 18 effect of speeds, feeds and depth of cut on finish and wheel life
• K 19 surface grinding techniques required to produce surfaces such as parallel, flat and square
• K 20 cylindrical and surface grinding techniques to produce profiles such as angles, vees, radii, recesses, shoulders and special forms
• K 21 setup and alignment techniques for machine accessories such as drive plates, grinder carriers, drive dogs, trip dogs, foot stock, centres, chucks, work heads and wheel heads
• K 22 types of tool and cutter grinders such as drill grinders and end mill grinders
• K 23 cutter types such as form relief cutters, reamers and end mills
• K 24 relief angles and clearances
• K 25 honing machines and techniques

Sub-task - B-8.01 Mounts grinding wheel.

Key Competencies

• B-8.01.01 visually inspect grinding wheel for defects such as cracks, stains and gouges
• B-8.01.02 ring test grinding wheel for internal cracks
• B-8.01.03 balance grinding wheel using wheel balancing equipment such as mandrels and weights
• B-8.01.04 secure grinding wheel on required adapters using blotters and flanges
• B-8.01.05 install balanced wheel assembly on machine
• B-8.01.06 select truing and dressing tools according to profile
• B-8.01.07 true and dress mounted grinding wheel using diamond dressing tools
• B-8.01.08 assess further balancing requirements of installed grinding wheel

Sub-task - B-8.02 Grinds flat surfaces.

Key Competencies

• B-8.02.01 touch off grinding wheel on workpiece surface to establish a reference point
• B-8.02.02 measure workpiece to determine amount of excess material using inspection equipment such as depth micrometers, gauge blocks and dial indicators
• B-8.02.03 remove required amounts of excess material to meet specifications
• B-8.02.04 identify surface finish defects caused by process problems such as incorrect speeds and feeds, depth of cut and wheel loading, and incorrect consistency of coolant
• B-8.02.05 verify flat surface meets specifications using inspection equipment such as profilometers, micrometers, surface finish comparators and dial indicators

Sub-task - B-8.03 Grinds profiles and tapered surfaces.

Key Competencies

• B-8.03.01 select profile grinding machine such as surface, universal and cylindrical grinder
• B-8.03.02 position and secure workpiece to work holding device
• B-8.03.03 dress grinding wheel to desired profile using tools such as radius dressing attachment, dressing stick (stone) and diamond dressing tool
• B-8.03.04 measure workpiece to determine amount of excess material using inspection equipment such as depth micrometers, sine bars, contour gauge, dial indicators and optical comparator (shadow graph)
• B-8.03.05 touch off grinding wheel on workpiece surface to establish a reference point
• B-8.03.06 perform internal, external, plunge or traverse grinding
• B-8.03.07 rough out workpiece profile to remove excess material leaving a finish grinding allowance
• B-8.03.08 verify profile meets specifications using inspection equipment

Task 9 Operates computer numerical control (CNC) machines.

Required Knowledge

• K 1 CNC machine controls
• K 2 programming codes such as G, M and S
• K 3 parameters to establish work datum
• K 4 types of offsets and compensations such as length, diameter and tool nose radius
• K 5 load monitoring system
• K 6 machine alarms and alarm codes
• K 7 Cartesian Coordinate System
• K 8 sequence of CNC machining operations
• K 9 conversational programming
• K 10 absolute and incremental programming methods
• K 11 types of probes and probing systems
• K12 work holding size and types for selected operation

Sub-task - B-9.01 Performs basic CNC programming.

Key Competencies

• B-9.01.01 interpret workpiece documentation such as setup sheets and engineering drawings
• B-9.01.02 locate information required for CNC machining such as part origin, orientation and location of work holding devices
• B-9.01.03 determine types of cutting tools to be used in machining operation
• B-9.01.04 generate program points using trigonometry and Cartesian Coordinate System
• B-9.01.05 use software and built-in features of the machine control to generate cutter paths
• B-9.01.06 designate offsets for tool nose radius, cutter radius, approach vectors and tool length compensation
• B-9.01.07 plan entry and exit moves to engage or cancel cutter compensation
• B-9.01.08 establish safety blocks of code to establish safe program restart point in order to cancel previous code and initialize machine at a start point
• B-9.01.09 use G code and conversational method to produce program
• B-9.01.10 interpret and review codes from program

Sub-task - B-9.02 Inputs program data into control memory.

Key Competencies

• B-9.02.01 select and download program from personal computer (PC), network or storage devices to CNC controller
• B-9.02.02 manually input program data
• B-9.02.03 edit program using input functions such as “insert”, “alter” and “delete”

Sub-task - B-9.03 Sets up workpiece datum.

Key Competencies

• B-9.03.01 verify location of work datum by referring to setup sheets
• B-9.03.02 manually adjust machine axes to locate designated datum surfaces of workpiece using tools such as probes, dial indicators and edge finders
• B-9.03.03 establish tool length such as pre-set and touch off cutting tool on suitable reference surface
• B-9.03.04 input datum information into specific machine offset register as determined by setup sheet or tooling list

Sub-task - B-9.04 Verifies programs.

Key Competencies

• B-9.04.01 confirm program reference number
• B-9.04.02 perform dry run in single block mode or graphic simulation of program in order to verify datum, tool path and tool sequence
• B-9.04.03 use features such as single block mode, distance to go, feed hold and feed override to step through program to avoid cutting tool interference with work holding devices
• B-9.04.04 modify program as required, then confirm and retain program modifications and update master file

Sub-task - B-9.05 Monitors machining processes.

Key Competencies

• B-9.05.01 recognize signs of tool wear such as poor finish, vibration and excessive noise
• B-9.05.02 assess tool wear by reading spindle and drive axis load meters, and checking workpiece sizes
• B-9.05.03 recognize chip control problems
• B-9.05.04 use machine overrides such as rapid override, and speed and feed override
• B-9.05.05 verify adequate coolant or air flow to facilitate chip removal, and maintain required surface finish and tool life
• B-9.05.06 correct problems such as chatter, tool failure, poor finishes and abnormal chip formations by adjusting speed and feed overrides
• B-9.05.07 restart program at correct tool and machine position once problems are corrected
• B-9.05.08 measure workpiece dimensions
• B-9.05.09 adjust offset values by calculating deviations according to workpiece dimensions

Task 10 Operates Electrical Discharge Machines (EDM).

Required Knowledge

• K 1 specific hazards such as fire and electric shock
• K 2 types of EDMs such as wire EDM, sink EDM and super drill EDM
• K 3 functions and capabilities of EDMs
• K 4 types of dielectric fluids
• K 5 fluid pressures
• K 6 types of electrode materials
• K 7 wire diameters and materials
• K 8 electrode sizes
• K 9 power settings
• K 10 work holding size and types for selected operation

Sub-task - B-10.01 Determines flushing methods.

Key Competencies

• B-10.01.01 select fluid for required application
• B-10.01.02 prepare electrode flushing holes to provide adequate fluid flow
• B-10.01.03 set up flushing nozzles to provide adequate fluid flow
• B-10.01.04 ensure correct flushing during operation to prevent arcing

Sub-task - B-10.02 Sets cutting conditions.

Key Competencies

• B-10.02.01 select electrode material such as graphite and copper
• B-10.02.02 select electrode or wire size according to workpiece requirements
• B-10.02.03 select power setting according to electrode material
• B-10.02.04 monitor control panel for information such as voltage and amperage
• B-10.02.05 maintain cutting conditions during operation to optimize cutting action