| 1 | 1a. Set turret lathes 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 • dimensional tolerance equivalent to BS 4500 or BS 1916 Grade 7 • surface finish 63µin or |
| 1.5 | µm • reamed and bored holes within H8 • screw threads BS medium fit • angles within +/- |
| 1.6 | degree |
| 1.7 | Determine what has to be done and how the machine will be set to achieve this |
| 1.8 | Mount and set the required workholding devices, workpiece and cutting tools |
| 1.9 | Select, mount and secure the workpiece using four of the following workholding devices: • hand chucks with hard jaws • hand chucks with soft jaws • power chucks with hard jaws • power chucks with soft jaws • jigs/fixtures • collet chucks |
| 1.10 | Use two of the following groups of turning tools: • solid high speed steel • brazed tungsten carbide • indexible tips (carbide, ceramic or diamond) |
| 2 | 1b. Set turret lathes for production (continued) | 2.1 | Select and mount the following types of lathe tools, to include eight of: • turning tools • facing tools • form tools • chamfer/radii • parting off tools • thread chaser • single point threading • boring bars • recessing tools • center drills • twist/core drills • solid reamers • expanding reamers • taps • dies • knurling tool |
| 2.2 | Mount tools in all of the following locations: • in front tool box • in rear tool post • vertically or tangentially in turret knee box • in boring bars (single and multiple) • in chucks or floating arrangements • to produce multiple cutting arrangements |
| 2.3 | Set the machine tool operating parameters to achieve the component specification |
| 2.4 | Set up the machine in accordance with instructions and specifications, to include all of the following: • position of workpiece • screw cutting mechanisms • linear feed rate • cutting fluid flow rate • position of turning tools in relationship to workpiece • workpiece revolutions per minute • depth of cut for roughing and finishing • machine guards/safety mechanisms |
| 2.5 | Set up the machine to produce internal and external profiles that include ten of the following: • flat faces • parallel diameters • stepped diameters • tapered diameters • drilled holes • bored holes • reamed holes • profile forms • internal threads • external threads • eccentric features • parting off • chamfers and radii • knurls/special finishes • grooves/undercuts • counter bores |
| 2.6 | Machine components made from one of the following types of material: • ferrous • non-metallic • non-ferrous |
| 2.7 | Check that all safety mechanisms are in place and that the equipment is set correctly for the required operations |
| 2.8 | Deal promptly and effectively with problems within their control and report those that cannot be solved |
| 3 | 2a. Know how to set turret lathes for production | 3.1 | Describe the specific safety precautions to be taken when setting up workholding devices and accessories, workpiece and turning tools on turret lathes |
| 3.2 | Describe the hazards associated with setting turret lathes (such as moving parts of machinery, handling turning tools, handling cutting fluids, airborne particles, tool breakage, power chucks, insecure components) lathes 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 turning tools 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 | Describe the basic principles of operation of the turret lathe and its accessories, and typical operations that they can perform |
| 3.7 | Explain how to handle and store turning tools safely and correctly |
| 3.8 | 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 |
| 3.9 | Explain how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing |
| 3.10 | Explain how to read and interpret drawings, and how to extract the relevant information |
| 3.11 | Describe the terminology used in turret lathe turning in relation to the activities undertaken |
| 3.12 | Describe the range of work holding methods and devices that are used on turret lathes (such as two, three and four jaw chucks, hand and power operated chucks, collet chucks, jigs and fixtures) |
| 4 | 2b. Know how to set turret lathes for production (continued) | 4.1 | Describe the use of hard and soft jaws in chucks, and the methods of boring out soft jaws to suit the workpiece |
| 4.2 | Describe the different types of turning tools that are used, and how they are selected, prepared and mounted to the machine tool holding devices (such as front tool box, rear tool box, turret head) |
| 4.3 | Describe the use of pilot bars and shoes for the turret and, why they need to be accurately aligned |
| 4.4 | Describe the need to produce a balanced turret arrangement with tools appropriately positioned around the turret stations |
| 4.5 | Describe the factors which determine speeds and feeds to be used (material, type of tooling, depth of cut, workpiece rigidity, machine condition, multiple cutting arrangements between turret and saddle, tolerance and finish required) |
| 4.6 | Explain how the various types of material will affect the feeds and speeds that can be used |
| 4.7 | Describe the types of cutting fluid that are used, and precautions to be taken when handling and using them |
| 4.8 | Explain how to set up the turret lathe and its accessories for the particular operations being performed |
| 4.9 | Describe the need to conduct trial runs, and to check that the machine is set up and producing the components correctly |
| 4.10 | Describe the problems that can occur with setting up the workholding devices, tooling and machine operating parameters, and what to do if problems occur |
| 4.11 | 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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