mem05 metal and engineering core units - learner guide
TRANSCRIPT
-
8/10/2019 MEM05 Metal and Engineering Core Units - Learner Guide
1/12
MEM05 Metal and Engineering
Training Package
Learner guide
Version 3
Training and Education Support
Industry Skills Unit
Meadowbank
Product Code: 5808
MEM05Metal and engineering
core units
-
8/10/2019 MEM05 Metal and Engineering Core Units - Learner Guide
2/12
Developed by Training & Education Support Industry Skills Unit, Meadowbank
TAFE NSW 2014
MEM05 Metal and engineering core units
AcknowledgmentsThe TAFE NSW Training and Education Support Industry Skills Unit, Meadowbankwould like to acknowledge the support and assistance of the following people in theproduction of this learner resource guide:
Safe Work Australia WorkCover NSW WorkSafe Victoria WorkSafety Act Govt
Writer:
Gordon McLeanTAFE NSW
Reviewers:Jim MilesChris ZvirblisStephen DaviesTAFE NSW
Project Manager:
Stephen DaviesEducation Programs ManagerTAFE NSW
EnquiriesEnquiries about this and other publications can be made to:
Training and Education Support Industry Skills Unit, Meadowbank Meadowbank TAFE
Level 3, Building J, See Street,
MEADOWBANK NSW 2114
Tel: 02-9942 3200 Fax: 02-9942 3257
The State of New South Wales, Department of Education and Training,TAFE NSW, Training and Education Support Industry Skills Unit,
Meadowbank, 2014.
Copyright of this material is reserved to TAFE NSW Training and EducationSupport Industry Skills Unit, Meadowbank. Reproduction or transmittal in wholeor in part, other than for the purposes of private study or research, and subject tothe provisions of the Copyright Act, is prohibited without the written authority of,TAFE NSW Training and Education Support Industry Skills Unit, Meadowbank
ISBN 978 1 74236 516 9
-
8/10/2019 MEM05 Metal and Engineering Core Units - Learner Guide
3/12
Developed by Training & Education Support Industry Skills Unit, Meadowbank
TAFE NSW 2014
MEM05 Metal and engineering core units
Table of Contents
Introduction .................................................................................. 9
1. General introduction ............................................................................ 9
2. Using this learner guide ....................................................................... 11
3. Prior knowledge and experience ........................................................... 12
Topic 1: Work, health and safety .................................................. 13
Unit of competency overview ................................................................... 13
Evidence from the workplace or workshop ................................................. 15
Knowledge content ................................................................................. 15
Review questions for topic 1 .................................................................... 28
Practical exercise 1 ................................................................................. 30
Topic 2: Planning .......................................................................... 33
Unit of competency overview ................................................................... 33
Knowledge content ................................................................................. 37
Review questions for topic 2 .................................................................... 39
Practical exercise 2 ................................................................................. 40
Topic 3: Quality ............................................................................ 41
Unit of competency overview ................................................................... 41
Knowledge content ................................................................................. 44
Review questions for topic 3 .................................................................... 50
Practical Exercise 3 ................................................................................. 52
Topic 4: Working with others ....................................................... 53
Unit of competency overview ................................................................... 53
Evidence from the workplace or workshop ................................................. 55
Knowledge content ................................................................................. 55
Review questions for topic 4 .................................................................... 59
Practical exercise 4 ................................................................................. 60
Topic 5: Measurement .................................................................. 61
Unit of competency overview ................................................................... 61
http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?- -
8/10/2019 MEM05 Metal and Engineering Core Units - Learner Guide
4/12
Developed by Training & Education Support Industry Skills Unit, Meadowbank
TAFE NSW 2014
MEM05 Metal and engineering core units
Evidence from the workplace or workshop ................................................. 62
Knowledge content ................................................................................. 63
Review questions for topic 5 .................................................................... 87
Practical exercise 5, Group 1 - Instrument identication.............................. 93
Practical exercise 5, Group 2 Size measurement ...................................... 94
Practical exercise 5, Group 3 Rule and calliper measurement ..................... 98
Practical exercise 5, Group 4 - Vernier calliper measurement ....................... 99
Practical exercise 5, Group 5 - Feeler gauging ..........................................100
Practical exercise 5, Group 6 - Measurement of angles with a protractor ......101
Practical exercise 5, Group 7 - Micrometer reading ....................................102
Practical exercise 5, Group 8 Freehand sketching ....................................103
Practical exercise 5, Group 9 Freehand sketching of circles and arcs ..........105
Practical exercise 5, Group 10 - Freehand sketching of complete sketches ....106
Topic 6: Organising and communicating
information ................................................................... 109
Unit of competency overview ..................................................................109
Knowledge content ................................................................................111
Topic 7: Providing on-the-job training ........................................ 113
Unit of competency overview ..................................................................113
Knowledge content ................................................................................115
Topic 8: Perform computations................................................... 117
Unit of competency overview ..................................................................117
Evidence from the workplace or workshop ................................................119
Knowledge content ................................................................................120
Review questions for topic 8, Group 1 ......................................................122
Review questions for topic 8, Group 2 ......................................................125
Review questions for topic 8, Group 3 ......................................................130
Review questions for topic 8, Group 4 ......................................................135
Review questions for topic 8, Group 5 ......................................................140
Review questions for topic 8, Group 6 ......................................................145
Review questions for topic 8, Group 7 ......................................................151
http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?- -
8/10/2019 MEM05 Metal and Engineering Core Units - Learner Guide
5/12
Developed by Training & Education Support Industry Skills Unit, Meadowbank
TAFE NSW 2014
MEM05 Metal and engineering core units
Review questions for topic 8, Group 8 ......................................................157
Review questions for topic 8, Group 9 ......................................................160
Review questions for topic 8, Group 10 ....................................................165
Review questions for topic 8, Group 11 ....................................................170
Review questions for topic 8, Group 12 ....................................................178
Review questions for topic 8, Group 13 ....................................................181
Review questions for topic 8, Group 14 ....................................................186
Topic 9: Computing technology .................................................. 203
Unit of competency overview ..................................................................203
Topic 10: Sustainable work practices ......................................... 207
Unit of competency overview ..................................................................207
Knowledge content ................................................................................208
How is sustainable manufacturing good for industry? .................................209
Role of the worker .................................................................................209
Toolkit recommendations ........................................................................213
What is a resource efciency issue? .........................................................218
Information sheet 10.1 - Key environmental issues and manufacturing .........225
Review questions ..................................................................................229
Answers to review questions ..................................................... 231
Resource Evaluation Form .......................................................... 247
http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?- -
8/10/2019 MEM05 Metal and Engineering Core Units - Learner Guide
6/12
TAFE NSW (Training & Education Support, Industry Skills Unit Meadowbank) 2014 Page 9 of 250
MEM05 Metal and engineering core units
Introduction
1. General introduction
Welcome to MEM05 Metal and engineering core units.
The eleven (11) national units of competency in this resource are core units fromthe MEM05 Metal and Engineering Training Package.
Core competencies deal with general skills and knowledge that are required by allpeople working at a particular level in the metal and engineering industry, whetherthey are, for example, a fabrication tradesperson, a mechanical tradesperson or aproduction worker.
The following are core units in the Certicate I in Engineering (MEM10105):
MEM13014A Apply principles of occupational, health and safety in the workenvironment
MEM14004A Plan to undertake a routine task
MEM15024A Apply quality procedures
MEM16007A Work with others in a manufacturing, engineering or relatedenvironment
The following are core unit in the Certicate II in Engineering (MEM20105):
MEM13014A Apply principles of occupational, health and safety in the workenvironment
MEM14004A Plan to undertake a routine task
MEM15002A Apply quality systems
MEM15024A Apply quality procedures
MEM16007A Work with others in a manufacturing, engineering or relatedenvironment
The following are core units in the Certicate II in Engineering ProductionTechnology (MEM20205):
MEM12023A Perform engineering measurements
MEM13014A Apply principles of work, health and safety in the workenvironment
MEM14004A Plan to undertake a routine task
MEM15002A Apply quality systems
MEM15024A Apply quality procedures
MEM16006A Organise and communicate information
-
8/10/2019 MEM05 Metal and Engineering Core Units - Learner Guide
7/12
Page 10 of 250 TAFE NSW (Training & Education Support, Industry Skills Unit Meadowbank) 2014
MEM05 Metal and engineering core units
MEM16007A Work with others in a manufacturing, engineering or relatedenvironment
MEM17003A Assist in the provision of on-the-job training
MSAENV272B Participate in environmentally sustainable work practices
The following are core units in the Certicate III and IV in Engineering qualicationssuch as MEM30105, MEM30205, MEM30305 and MEM40105.
MEM12023A Perform engineering measurements
MEM12024A Perform computations
MEM13014A Apply principles of work, health and safety in the workenvironment
MEM14004A Plan to undertake a routine task
MEM14005A Plan a complete activity
MEM15002A Apply quality systems
MEM15024A Apply quality procedures
MEM16006A Organise and communicate information
MEM16007A Work with others in a manufacturing, engineering or relatedenvironment
MEM16008A Interact with computing technology
MEM17003A Assist in the provision of on-the-job training
MSAENV272B Participate in environmentally sustainable work practices
It is expected that while the technical competencies are being addressed the coreunits of competency will also be developed in parallel with your study program. Formost of these core units, it is not expected that they will be directly addressed indelivery that is, it may be unlikely that dedicated classes will run to address them.Nevertheless, each core unit will need to be assessed. To assist in achieving thisoutcome this workbook provides content and assessment guidelines.
R ev i e w q u e s t io n s
At the end of each topic there are review questions to help you understand,summarise and revise what you are learning. They are not tests or exams so your
teacher will not be formally marking them.
-
8/10/2019 MEM05 Metal and Engineering Core Units - Learner Guide
8/12
TAFE NSW (Training & Education Support, Industry Skills Unit Meadowbank) 2014 Page 11 of 250
MEM05 Metal and engineering core units
2. Using this learner guide
This learner guide may be used on its own, or it may be used as additional materialto support the development of knowledge and skills required to achieve a particular
core unit of competency.
Gr o u p l e ar n i n g
If you are studying these units of competency as part of a group of learners yourteacher will guide you in how to use these materials, including which learning topicsand exercises should be completed.
L ea r n i n g s t r a t e g i e s
This learner guide contains a variety of different learning activities to supportthe skills required to achieve the core units of competency. In addition to theactivities described in this guide, it is important that you discuss the issues raisedwith others such as your colleagues, practitioners working in the eld and otherlearners. Discussion plays an important role in understanding and remembering newinformation.
To promote active learning:
1. Come up with your own answers rst, before you attempt any readings
2. Compare and discuss your answers with others.
3. Research the topic and access readings, videos, other examples etc.
4. Ask yourself, What do I think about this unit now that I have studied it in depth?What have I learned?
The learner guide is designed for you to work at your own pace and at a timeconvenient for you. It also allows you to self-direct and control your learning.
There may be some tutorials, practical sessions or workshops which you arerequired to attend. If this is required you will be notied of the times and dates ofthese activities at the commencement of the unit(s).
You also have access to tutorial support. This is an additional support service thatcan help you with time management, study skills, editing of your work, organisationand even literacy skills. It is important for you to contact your teacher and ask for
this support if you require it. Normally this service is accessed at your nearest TAFECollege.
You may also need to access resources at a TAFE college or library. These resourcesmay include computer facilities and software, books, library material and videos.The resources are listed under the resources heading for this unit and references tothese resources are made at the relevant sections of the guide.
When working through the material there may be reference to legislation orregulations. Over time legislation and regulations may change. It is important thatyou access the most current version. Refer to your teacher if you are unsure.
-
8/10/2019 MEM05 Metal and Engineering Core Units - Learner Guide
9/12
-
8/10/2019 MEM05 Metal and Engineering Core Units - Learner Guide
10/12
Page 176 of 250 TAFE NSW (Training & Education Support, Industry Skills Unit Meadowbank) 2014
MEM05 Metal and engineering core units
Example: A pinion is revolving at 375 rev/min and is in mesh with a gear of80 teeth revolving at 150 rev/min. Find the number of teeth in thepinion.
Solution: Speed ratio =2
5
150
375
gearofSpeed
pinionofSpeed ==
Gear Ratio =5
2
gearinTeeth
pinioninTeeth=
Let P, represent the number of teeth in the pinion
5
280P
5
2
80
P
=
=
Answer: P = 32 teeth
Example: A vee belt drive has a pulley 210 mm diameter on a motor revolvingat 900 rpm, driving a 120 mm diameter pulley on a grinding machinespindle.
What will be the rpm of the grinding machine?
120 mm210 mm
Motor
Solution: Pulley diameter ratio4
7
120
210
pulleydrivenofDiameter
pulleydriverofDiameter ==
The speed ratio is the reciprocal of the pulley ratio =7
4
That is, speed ratio =7
4
drivenofSpeed
driverofSpeed=
-
8/10/2019 MEM05 Metal and Engineering Core Units - Learner Guide
11/12
TAFE NSW (Training & Education Support, Industry Skills Unit Meadowbank) 2014 Page 177 of 250
MEM05 Metal and engineering core units
Let Nrepresent the speed of the grinder (the driven pulley).
7
4
N
900=
4
9007N
=
Answer: N = 1575 rev/min
Example: A single-start worm revolving at 1400 rev/min is driving a 30-toothworm wheel. Find the speed of the worm wheel.
Solution: A single-start worm may be regarded as a one-tooth gear, becauseone revolution of the worm rotates the worm wheel one tooth.Likewise, a two-start worm may be regarded as a two-toothed gear, a
three-start worm a three-toothed gear and so on.
Worm wheel30 teeth
Single-startworm 1400 rpm
Gear ratio =30
1
wheelworminTeeth
wormofStarts=
Velocity ratio =1
30
wheelwormofSpeed
wormofSpeed=
Let N represent the speed of the worm wheel.
30
1400N
1
30
N
1400
=
=
Answer: N = 47 rev/min
-
8/10/2019 MEM05 Metal and Engineering Core Units - Learner Guide
12/12
Page 178 of 250 TAFE NSW (Training & Education Support, Industry Skills Unit Meadowbank) 2014
MEM05 Metal and engineering core units
Review questions for topic 8, Group 12
1. A casting weighing 8 kg cost $2.40. What would be the price of another casting
weighing 14 kg, if the cost was at the same rate?
2. The mechanical advantage (MA) of a machine is a ratio of the load moved to theeffort applied,
MA =Load
Effort
Determine the missing values in the table of information below.
Mechanicala d v a n t a g e
Lo a d m o v e d Ef f o r t a p p l i e d
(a)
(b)
(c)
(d)
(e)
(f)
10
3.5
18
32
550 kN
70 kN
360 kN
512 kN
11 kN
50 kN
40 kN
24 kN
3. A concrete specication calls for a mixture of aggregate, sand and cement in theratio of 5:2:1. What weights of aggregate, sand and cement will be required tomake 1 tonne of dry mix?
4. Determine the missing values in the table of information on belt drives below.
Drivingpulley
diameter
Drivingpulley
rev/min
Drivenpulley
diameter
Drivenpulley
rev/min
Driver/driven
diameterratio
Driver/driven
velocityratio
(a)
(b)
(c)
(d)
6 in
7 in
360 mm
450
220
18 in
315 mm
120
320
1:5
8:3
1:4.5