| 1 | 1a. Set automatic spring end grinding 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 interpret correctly the documentation for the type of spring to be ground (such as job instructions, spring drawings and quality 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 • check that the machine and workholding device to be used is in a safe and usable condition • carry out the setting-up activities, following good practice/approved procedures • ensure that grinding wheels are correctly dressed/formed and are in a usable condition • hold components securely, without distortion • ensure that correctly adjusted machine guards are in place • leave the machine and work area in a safe and clean condition on completion of the setting-up activities |
| 1.3 | Follow the correct specifications for the component to be produced |
| 1.4 | Determine what has to be done and how the machine will be set to achieve this |
| 1.5 | Prepare one of the following types of automatic spring end grinding machine in readiness for production: • single end • double end |
| 1.6 | Mount and set the required workholding devices, workpiece and cutting tools |
| 1.7 | Position and secure the springs, using three of the following workholding methods and devices: • loading plate • pots • magnetic table • bushes • fixtures |
| 1.8 | Select and mount grinding wheels, to include all of the following: • selecting grinding wheels for specific materials and applications (such as grain size, grade, structure, bond) • testing wheels for soundness/cracks • mounting wheels (such as paper washers, flanges, locking pressure) • balancing wheels, where appropriate • dressing and ‘trueing up’ grinding wheels |
| 1.9 | Set the machine tool operating parameters to achieve the component specification |
| 2 | 1b. Set automatic spring end grinding machines for production (continued) | 2.1 | Grind components made from two of the following types of material: • carbon steel • stainless steel • alloy steel • copper based alloy • nickel based alloys • titanium and other special material |
| 2.2 | Use one of the following methods when grinding the springs: • crash grinding • down-feed grinding |
| 2.3 | Set up the spring end grinding machines in accordance with instructions and specifications, to include all of the following, as appropriate: • mounting and securing the appropriate loading plate/fixture to the machine • checking springs for cleanliness and freedom from burrs, reaming and edging if required • loading springs in the fixture, using bushes, where appropriate • setting guards and safety mechanisms and checking that they operate correctly • setting the grinding machine to grind one or both ends, as appropriate to the machine type • setting to give equal tip end thickness • setting automatic trips and limit switches • checking that spring length, squareness and finish are to specification |
| 2.4 | Check that all safety mechanisms are in place and that the equipment is set correctly for the required operations |
| 2.5 | Carry out checks of the springs, to include all of the following: • free length • squareness • coil diameter of end • solid length • tip end thickness • finish |
| 2.6 | Use four of the following whilst checking the quality of the springs produced: • Vernier callipers • micrometers • spring testing machines • Vernier protractors • squares • electronic measuring equipment • gauges • jigs |
| 2.7 | Set up automatic spring end grinding machines, to grind spring ends to meet one of the following: • BS, ISO or BSEN standards and procedures • customer standards and job requirements • company standards and procedures |
| 2.8 | Complete all relevant documentation on completion of the spring grinding activities, to include one of the following: • job cards • quality control documentation • company-specific documentation • computer records • test documents |
| 2.9 | Deal promptly and effectively with problems within their control and report those that cannot be solved |
| 3 | 2a. Know how to set automatic spring end grinding machines for production | 3.1 | Describe the specific safety precautions to be taken when setting up workholding devices and grinding wheels on automatic spring end grinding machines (such as single or double ended) |
| 3.2 | Describe their duties and responsibilities under The Abrasive Wheels Regulations, with particular reference to the mounting of abrasive wheels |
| 3.3 | Describe the hazards associated with spring end grinding (such as moving parts of machinery, sparks/airborne particles, the possibility of fire when grinding titanium, bursting grinding wheels, insecure components), and how to minimise them and reduce any risks |
| 3.4 | Explain how to start and stop the machine in normal and emergency situations |
| 3.5 | Describe the importance of ensuring that the machine is isolated from the power supply before mounting grinding wheels and workholding devices |
| 3.6 | Describe the importance of wearing the appropriate protective clothing and equipment, and of keeping the work area clean and tidy |
| 3.7 | Describe the basic operation of the spring end grinding machine, and typical operations that they can perform |
| 3.8 | Explain how to handle and store grinding wheels, safely and correctly |
| 3.9 | Explain how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS or ISO standards) in relation to work undertaken |
| 3.10 | Explain how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing |
| 3.11 | Describe the terminology used in spring end grinding, in relation to the activities undertaken |
| 3.12 | Describe the range of workholding methods and devices that are used on the spring end grinding machines |
| 3.13 | Describe the methods of mounting and setting the springs in the workholding devices, and the tools and equipment that are to be used for this |
| 4 | 2b. Know how to set automatic spring end grinding machines for production (continued) | 4.1 | Describe the selection of grinding wheels with regard to the type of material being ground and operations being carried out |
| 4.2 | Explain how the various types of spring material will affect the feeds and speeds that can be used |
| 4.3 | Explain how to check that the grinding wheels are in a safe and serviceable condition (such as free from damage, cracks, correctly balanced) |
| 4.4 | Explain how grinding wheels are balanced, and the equipment that is used for this |
| 4.5 | Describe the methods of mounting and securing the grinding wheels to the machine spindles |
| 4.6 | Explain the need for ‘trueing up’ and frequent dressing of wheels to prevent glazing and burning of the spring surface |
| 4.7 | Explain how to set up the machines for the particular operations being performed |
| 4.8 | Describe the application of cutting fluids with regard to a range of different materials |
| 4.9 | Explain the need to conduct trial runs, and to check that the machine is set up and running safely and correctly |
| 4.10 | Describe the organisational quality control procedures, and the recognition of grinding defects |
| 4.11 | Describe the problems that can occur with setting up of the grinding wheels, workholding devices and machine operating parameters, and what to do if problems occur |
| 4.12 | Describe the importance of completing all relevant documentation on conclusion of the spring grinding activities |
| 4.13 | 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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