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STUDENT WORKBOOKVersion: March 2012
Unit Name:Perform milling operations
Student Name: _____________________________________________________
Student Number: ___________________________________________________
Assessment OutcomeDateTeachers signature
Assessments requirements: Completed satisfactorily
Assessment requirements: Not yet complete NOTE: Teacher & Student to sign the: To be Completed Notification Form - (last page of this workbook)
Instructions to students:
This workbook is a major component of the assessment for this competency, all Questions and Projects, MUST BE COMPLETED and signed off by your teacher.
It is the students responsibility to complete the Assessment Requirements, listed in this workbook and to ensure that teachers progressively sign off requirements as they are completed. (Teachers must not sign off work they have not witnessed completed)
When completed the Assessment Outcome (above) is to be signed by your teacher.
This workbook is to be retained by the student as their record of the completion of this competency.
Compulsory Assessment Requirements
Assessment/ProjectCompletion DateTeachers signature
Student Safety Requirements for Workshops Form Signed
1 Overarm machined to specifications
2 Base Plate machined to specifications
3 Pinion Gear machined to specifications
4 Rack machined to specifications
5 Assignment completed satisfactorily
6 Quality control task - Overarm measured
7 Final Examination
ContentsSection 1:Unit of Competency6Competency Descriptor6Competency Unit Resources7Assessment Strategies8Lesson Schedule9Section 2: Assessment Tasks10Assessment Task No110Assessment Task No210Assessment Task No310Assessment Task No410Assessment Task No510Assessment Task No610Assessment Task No710Assessment Task No810Section 3: Observe Safety Precautions11Workshop Safety11Review Questions Observe Safety Precautions21Section 4: Determine Job Requirements23Introduction23Instructions and specifications24Sequence of Operations25Tooling27Cutting fluids40Cutting Parameters43Review Questions Determine Job Requirements49Section 5 Perform milling operations60Setting up work holding devices60Types of Vice62Review Questions Setting up workholding devices77Setting up a workpiece79Setting cutters83Mounting and centralising gear cutters84Centralising the cutter85Dividing Heads86Calculations for Indexing89Review Questions Setting workpieces, Cutters, Indexing94Types of milling operation99Milling machine attachments104Review Questions Milling operations , Milling machine attachments108Section 6 Check components for conformance with specificiations111Introduction111Direct measurement tools111Comparative measurement tools120Recording size conformance127Review Questions Check components for conformance128Section 7 Drawing appendix130Arbor Press - Sheet 1130Arbor Press Sheet 2131Arbor Press Sheet 3132Arbor Press Sheet 4133Arbor Press Sheet 5134Section 8 - Risk Management135
Section 1:Unit of CompetencyCompetency DescriptorUnit descriptor This unit covers performing milling operations on a range of milling machines.
Prerequisites MEM07005B Perform general machiningMEM09002B Interpret technical drawingMEM12023A Perform engineering measurementsMEM18001C Use hand tools
Competency field Machine & process operations
Application of the competency This unit applies to a range of milling machines including vertical, horizontal and universal types, a range of precision measuring equipment and cutting tools.Work is performed to established processes, practices and to drawings, sketches, specifications and instructions as appropriate. Cutting tools are selected using International Standard Organisation (I.SO) standards or according to standard operating procedure as appropriate.
Unit Weight 4
ElementsPerformance criteria (sample list)
1. Observe safety precautions1.1 Correct safety procedures are observed and protective clothing and safety glasses worn. 2. Determine job requirements2.1 Drawings are interpreted, sequence of operation is determined and tooling is selected to produce component to specification.2.2 Cutting parameters are determined.
3. Perform milling operations3.1 Milling operations are carried out to produce components to specification.3.2 Operations are undertaken using conventional and/or climb milling techniques and a variety of cutters including slab, gang, end shell, slot, form and slitting.3.3 The full range of standard accessories is used including dividing heads and rotary tables as required
4. Check components for conformance 4.1 Components are checked for conformance to specification using with specifications appropriate techniques, tools and equipment
Competency Unit Resources
Prescribed Text:No text book has been set for this competency.
However, there are many books that cover "Fitting and Machining" in the Institute Library. You are able to access these at any time.
Fitting and Machining, Culley, Ron ED., 1996, TAFE Publications, Collingwood, Vic
Principals of Machine Maintenance, Dick Jeffrey. (Yeronga Lib. No. - TJ 1040 .J43 1991)
Basic Training Manual: Workshop Safety, 1999, Australian Training Products Ltd, Melbourne
Basic Training Manual: Hand and Power Tools, 1999, Australian Training Products Ltd, Melbourne
Machine Shop Technology Vol 1, Maskiell & Galbraith, 1984, McGraw-Hill Book Company
Engineering Drawing Handbook, The Institution of Engineers Australia.. (Lib. No. - T 357.E53 1993)
Australian Standards:AS1100 - Technical drawingAS1101 Graphical symbols for general engineeringAS1654 Limits and fits for engineeringAS2536 Surface Texture
The following table indicates the strategies used to assess the underpinning knowledge and first practice deemed necessary to be successful in the Off the Job component of this CSU.To be deemed competent, students must satisfy the criteria stipulated by the Metals & Engineering National Training Package assessment in the workplace as well as the Off the Job component.
Element CriteriaTheory ExaminationPractical ExercisesAssignment Presentation
Students will complete and submit for feedback all nominated exercises from the supplied resource book.All exercises must be completed and will include application of learned techniques, skills and practices listed for this Competency Standard Unit.
Method of assessment Assessors should gather a range of evidence that is valid, sufficient, current and authentic. Evidence can be gathered through a variety of ways including direct observation, supervisors reports, project work, samples and questioning. Questioning techniques should not require language, literacy and numeracy skills beyond those required in this unit of competency. The candidate must have access to all tools, equipment, materials and documentation required. The candidate must be permitted to refer to any relevant workplace procedures, product and manufacturing specifications, codes, standards, manuals and reference materials.
Lesson Schedule The following lesson schedule is suggested for the delivery of content by teachers and also to allow students time to display evidence of the underpinning knowledge they have gained and practical application required MEM07007C
Lesson 1(4 hours)Introduction to Competency: Check for new students & perform orientation if required; Discuss course activities, assessment procedures (theory & practical);Milling machines in general, SAFETY and machine maintenance requirements (Section 1 of workbook)Operational planning for milling (Section 7 of workbook)Indexing theory and calculation exercises (Section 5 of workbook)Basic gear calculations for Rack and Pinion; OD, Depth of Cut, Transverse PitchGroup exercise Setting up machine to cut pinion. Teacher to explain procedures while students set up machine. Students to take notes for Assignment detailing all set up procedures and calculations needed. ** Assignment to be submitted by third day for preliminary assessment **
Lesson 2(4 hours)Theory Delivery: Cutters, mounting cutters, cutting parameters, work holding, operations (Sections 2,3,4,6 of workbook) accurate setting up vicesTeacher to discuss each of the milling job requirements in detailStudents to set up milling machines, two set up for facing ends of (column spindle) Base and Overarm, One machine set up for cutting pinion gear. One machine with rotary table for Base. Vertical mill for Base holes, Two machines set up for end slot on Overarm. (column spindle). Two for blocking the Rack (vertical spindle) Students to pair up where necessary.
Lesson 3(4 hours)Teacher to Discuss need for toolmakers button on Overarm (stepped bore end) lathe set up with fixture. Students to continue with PRACTICAL work
Lesson 4(4 hours)Students to continue with PRACTICAL workStudents to submit assignment no later than beginning of lesson 6
Lesson 5(4 hours)Teacher to assess assignments and return for rework if necessaryPractical Work: Student to continue with practical workAssignment Work: Students to rework assignment if necessary and re-submit
Lesson 6(4 hours)Practical Work: Student