| 1 | 1a. Set gear cutting machines for production | 1.1 | Work safely at all times, complying with health and safety and other relevant regulations and guidelines |
| 1.2 | Carry out all of the following activities during setting up: • obtain and use the appropriate documentation (such as job instructions, drawings, quality control documentation) • adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work • follow safe practice/approved setting up procedures at all times • ensure that correctly adjusted machine guards are in place • check that cutting tools are in a suitable condition • hold components securely without distortion • leave the work area and machine in a safe and appropriate condition on completion of the activities |
| 1.3 | Follow the correct specifications for the component to be produced |
| 1.4 | 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 • straight splines and serrations to BS 2059 or BS1953 Class 1 • spur and helical gears to BS 436 Pt 1 or BS1967 • involute splines to BS 3550 1963 Class 1 • tolerance to BS 4500 or BS1916 Grade 9 • surface texture 63 µin or |
| 1.5 | µm |
| 1.6 | Determine what has to be done and how the machine will be set to achieve this |
| 1.7 | Set up two of the following types of machine: • gear hobbing • gear shaping • bevel gear cutting • gear planing • gear shaving |
| 1.8 | Mount and set the required workholding devices, workpiece and cutting tools |
| 1.9 | Select, mount and secure the workpiece using two of the following workholding devices: • arbors • mandrels • chucks • pots • collets • fixtures • centres • clamps • face plates |
| 2 | 1b. Set gear cutting machines for production (continued) | 2.1 | Select and mount to the appropriate tool holding device, four of the following types of gear cutting tools: • shank type hobs • protuberance hobs • skiving hobs • inserted blade hobs • tapered hobs • single or multi-start straight hobs • bevel gear roughing cutters • bevel gear finishing cutters • disc type shaping/shaving cutters • shank type shaping/shaving cutters • extended hub type shaving cutters • screwed hub type shaping/shaving cutters • special cutters • rack type gear planing roughing cutters • single tooth gear planing roughing cutters • rack type full fillet planing finishing cutters • single tooth full fillet planing finishing cutters |
| 2.2 | Set the machine tool operating parameters to achieve the component specification |
| 2.3 | Prepare the machine by carrying out all the following activities applicable to the machine type: • set the slide angles • set the speed and feed rates • fitting differential/index change gears • select and set climb or conventional hobbing • set other machine operating parameters • select and fit appropriate index change gears and differential gears • select/set shaving method (axial or conventional, tangential or underpass, diagonal or plunge) |
| 2.4 | Set up the machine to produce machined components that include two of the following: • external spur gear • internal spur gear • single helical gear • double helical gear • chain sprockets • serrations • splines • straight bevel gears |
| 2.5 | Machine components made from one of the following types of material: • ferrous • non-metallic • non-ferrous |
| 2.6 | Check that all safety mechanisms are in place and that the equipment is set correctly for the required operations |
| 2.7 | Deal promptly and effectively with problems within their control and report those that cannot be solved |
| 3 | 2a. Know how to set gear cutting machines for production | 3.1 | Describe the specific safety precautions to be taken when setting up workholding devices and tooling on gear cutting machines. |
| 3.2 | Describe the hazards associated with setting gear cutting machines (such as moving parts of machinery, handling gear cutters, handling cutting fluids, airborne particles, tool breakage, insecure components) and how to minimise them and reduce any risks |
| 3.3 | Explain how to start and stop the machine in normal and emergency situations |
| 3.4 | Describe the importance of ensuring that the machine is isolated from the power supply before mounting cutters and workholding devices |
| 3.5 | Describe the importance of wearing the appropriate protective clothing and equipment, and of keeping the work area clean and tidy |
| 3.6 | Explain how to handle and store gear cutting tools safely and correctly |
| 3.7 | Explain how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS, ISO or BSEN standards) in relation to work undertaken |
| 3.8 | Explain how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing |
| 3.9 | Describe the terminology used in gear cutting in relation to the activities undertaken |
| 3.10 | Describe the range of workholding methods and devices that are used on gear cutting machines |
| 4 | 2b. Know how to set gear cutting machines for production (continued) | 4.1 | Describe the methods of mounting and setting the workpiece in/on the workholding devices, and the tools and equipment that can be used |
| 4.2 | Describe the various gear cutting operations that are used to produce the required gear forms, and the types of tooling used (such as straight hobs having single and multi start, tapered hobs, shank type hobs, protuberance hobs, inserted blade hobs, skiving hobs, disc and shank type gear shaping and shaving cutters, gear planing cutters and bevel gear cutters) |
| 4.3 | Explain how to check that the gear cutting tools are in a safe and serviceable condition |
| 4.4 | Describe the various tool holding devices that are used, and the methods of mounting and securing the gear cutting tools to the tool holders and machine spindles |
| 4.5 | Explain how to set up the various machines for the particular gears being machined |
| 4.6 | Explain how the various types of material will affect the feeds and speeds that can be used |
| 4.7 | Describe the application of cutting fluids with regard to a range of different materials, and why some materials do not require the use of cutting fluids |
| 4.8 | Describe the need to conduct trial runs, and to check that the machine is set up and running safely and correctly |
| 4.9 | Describe the problems that can occur with setting up of the tooling, workholding devices and machine operating parameters, and what to do if problems occur |
| 4.10 | Describe the extent of their own responsibility and to whom they should report if they have problems that they cannot resolve |
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