| 1 | 1a. Produce off-line programs for NC/CNC gear cutting machines | 1.1 | Work safely at all times, complying with health and safety and other relevant regulations and guidelines |
| 1.2 | Produce computer control programs that contain all the relevant and necessary data for the engineering activity to be carried out |
| 1.3 | Carry out all of the following, in preparation for the NC/CNC programming: • check that all the equipment is correctly connected, and is in a safe and usable condition (such as cables undamaged, correctly connected, safely routed) • power up the equipment and activate the programming software • set up the computer system to be able to produce the program • ensure that they have the necessary component data and information to produce the program • identify and deal with problems (such as information based and/or technical) |
| 1.4 | Carry out all of the following, as applicable to the programming method selected: • import the component data file and/or produce the shape/geometry of the component • select a suitable or specified datum point • select absolute and/or incremental system of measurement • select imperial or metric system of measurement • input material parameters • input the safe start position • select or create tool/cutter information (such as number, type, lengths and offsets, radius compensation) • select appropriate reference codes • input the required positional information • input cutting parameters (such as depth of cut, direction, feed in/out) • input preparatory commands and machine management/auxiliary functions • use repetitive programs (sub-routines, canned cycles, labels, macros) • determine tool/cutter path order and sequence • select and input tool ... |
| 1.5 | ... change positions • input any additional information (such as a work-shift position) • convert the program into the correct format (post processing) |
| 1.6 | Produce gear cutting programs, combining different operations that will produce five of the following: • external spur gears • internal spur gears • external helical gears • internal helical gears • straight splines • involute splines • serrations • bevel gears • racks |
| 1.7 | Produce the control programs in the appropriate formats |
| 2 | 1b. Produce off-line programs for NC/CNC gear cutting machines (continued) | 2.1 | Make sure that codes and other references used in the programs are applicable to the type of controller used |
| 2.2 | Produce programs, using one of the following methods: • computer aided machining (CAM) • G code • conversational code • other specific method (such as macros) |
| 2.3 | Pass on the programs to the appropriate people, within agreed timescales |
| 2.4 | Save and back up the program detail, and store securely in accordance with organisational requirements |
| 2.5 | Carry out all of the following on completion of the programming activity: • check and review the program format and content • edit the program using the correct procedure (where appropriate) • produce tooling sheets (to include information such as tool identification, tips, fixtures and methods of setting up, where appropriate) • check that the program is correctly titled and referenced • ensure that programs are stored safely and correctly, in the correct format and location • ensure that the program has been checked and approved before forwarding to the end user • send the approved program to the correct location for the end user • create a separate back-up copy of the program, in case of file corruption |
| 2.6 | Undertake changes to program details, within agreed control procedures |
| 3 | 2a. Know how to produce off-line programs for NC/CNC gear cutting machines | 3.1 | Describe the specific safety precautions to be taken when working with computer systems (to include safety guidance relating to the use of visual display unit (VDU), equipment and workstation environment(such as lighting, seating, positioning of equipment), repetitive strain injury (RSI); the dangers of trailing leads and cables; how to spot faulty or dangerous electrical leads, plugs and connections) |
| 3.2 | Describe the good housekeeping arrangements (such as cleaning down work surfaces; putting disks, manuals and unwanted items of equipment into safe storage; leaving the work area in a safe and tidy condition) |
| 3.3 | Describe the basic set-up and operation of the computer system, and any peripheral devices that are used |
| 3.4 | Describe the correct start-up and shutdown procedures to be used for the computer system |
| 3.5 | Explain how to access the specific programming software, and the use of manuals and related documents to solve problems and aid the efficient programming of NC/CNC gear cutting machines |
| 3.6 | Describe the importance of protecting the computer system from viruses, and the implications if the correct procedure is not followed |
| 3.7 | Explain how to power up, log on and activate the computer system and programming software correctly |
| 3.8 | Explain how to deal with system problems (such as error messages received, peripherals which do not respond as expected) |
| 3.9 | Describe the checks to be carried out to ensure that peripheral devices are connected correctly |
| 3.10 | Describe the correct procedure to shut down the operating and programming system |
| 3.11 | Explain how to create and structure directories and files correctly (such as importing, copying, transferring, exporting, deleting, backing up and saving files) |
| 3.12 | Describe the different types of storage media that can be used to save program files |
| 3.13 | Describe the off-line programming methods used in NC/CNC gear cutting (such as computer aided machining (CAM), G code and conversational code) |
| 4 | 2b. Know how to produce off-line programs for NC/CNC gear cutting machines (continued) | 4.1 | Describe the different programming codes used to identify factors such as machine axes, positional information, tooling identification and selection, tool/cutter direction, material removal, speeds and feeds, machine management and auxiliary functions |
| 4.2 | Describe the main machine controllers that are available, and the importance of understanding that a different machine controller may use completely different codes for similar functions |
| 4.3 | Describe the information and data required in order to produce complete and accurate NC/CNC gear cutting programs |
| 4.4 | Explain how to extract and interpret general and technical data and information from different sources (such as drawings, computer models, symbols and conventions,BS or ISO standards), in order to produce the NC/CNC gear cutting program |
| 4.5 | Describe the factors to be taken into account when producing NC/CNC programs (including the type of CNC gear cutting machine and its machining capabilities, the tooling available, safety, workholding equipment, the material being machined, component tolerances and surface finish required) |
| 4.6 | Describe the different methods used to set tooling, such as manual methods, probing and setting arms |
| 4.7 | Explain how to produce effective and efficient programmes to avoid unnecessary operations, tool movements and tool changes (including the use of macro programs and canned cycles, to reduce program size) |
| 4.8 | Describe the methods and procedures used to check that the completed program will produce the required component safely, accurately and efficiently |
| 4.9 | Explain how to save the completed programs in the appropriate format, and the need to store programs safely and correctly, away from contaminants and electromagnetic sources |
| 4.10 | Explain how to back up completed or edited programs, and the implications if this is not carried out effectively |
| 4.11 | Describe the problems that can occur with the downloading and running of the NC/CNC gear cutting program, and how these can be overcome |
| 4.12 | Describe the correct procedure to be followed before the program is released to the end user |
| 4.13 | Describe the extent of their own responsibility and to whom they should report if they have any problems that they cannot resolve |
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