| 1 | 1a. Prepare and prove CNC machine tool programs | 1.1 | Work safely at all times, complying with health and safety legislation, regulations and other relevant guidelines |
| 1.2 | Ensure that they apply all of the following checks and practices at all times during the programming activities: • adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations • the correct component drawings are obtained and checked for currency and validity • the appropriate reference manuals and programming codes are used to suit the machine controller • the machine controller is prepared ready to accept the operating program • the prepared program is input/loaded into the controller safely and correctly • programs are stored safely and correctly in the appropriate format • program media is stored safely and correctly, away from contaminants or electromagnetic sources |
| 1.3 | Prepare and prove programs for one of the following types of CNC machine tool: • two axis machine • three axis machine • multiple axis machines (5 or more) • machining centres |
| 1.4 | Plan the programming activities before they start them |
| 1.5 | Determine an operational sequence that avoids wasted tool/cutter movements and tool changes |
| 1.6 | Develop component programs using appropriate programming codes and techniques |
| 1.7 | Produce CNC programs using one of the following methods: • written • entered directly into the machine controller • using computer software |
| 1.8 | Develop part programs which contain all of the following, as applicable to the machine type: • all necessary positional information • appropriate letter address codes • machine management commands (preparatory/auxiliary functions) • repetitions within programs (using features such as subroutines, canned cycles, labels) • absolute or incremental co-ordinates • tool/cutter change positions • tool information (such as lengths, offsets, radius compensation) |
| 1.9 | Develop programs to produce components which cover eight of the following features: • parallel diameters • stepped diameters • tapered diameters • flat faces • internal undercuts • external undercuts • steps/shoulders • parallel faces • faces that are square to each other • angular faces • internal profiles • external profiles • reamed holes • tapped holes • drilled holes • holes on pitched circles • holes linearly pitched • parting-off • enclosed slots/recesses • open ended slots • eccentric diameters • external screw threads • internal screw threads • chamfers and radii • bored holes • special forms (such as concave, convex) |
| 2 | 1b. Prepare and prove CNC machine tool programs (continued) | 2.1 | Develop part programs to machine components made from two of the following types of material: • low carbon/mild steel • high carbon steel • aluminium/aluminium alloys • cast iron • brass/brass alloys • plastic/nylon/composite • other specific material |
| 2.2 | Specify positional information and machine axes that are consistent with the requirements of each stage/operation |
| 2.3 | Load/input the program to the machine controller, and check/prove the program for errors using approved procedures |
| 2.4 | Confirm that the program operates safely and correctly, by checking all of the following: • datums for each machine axis are set in relation to all equipment and tooling used • all operations are carried out to the program co-ordinates • tool change positions are safe and clear of the workpiece and machine equipment • the correct tools are selected at the appropriate points in the program • tool offsets are correctly entered into the machine controller • tool cutter paths are executed safely and correctly • auxiliary functions operate at the correct point in the program (cutter start/stop, coolant flow) • programs have been saved in the appropriate format |
| 2.5 | Prove the part program using six of the following: • single block mode • graphic simulation • data input facilities • full dry run (in air) • search facilities • edit facilities • program override controls (spindle speed, feed rate, tool data) • program save/store facilities |
| 2.6 | Save and store the program in line with organisational procedures |
| 2.7 | Deal promptly and effectively with problems within their control, and seek help and guidance from the relevant people if they have problems that they cannot resolve |
| 2.8 | Shut down the equipment to a safe condition on completion of the programming activities |
| 3 | 2a. Know how to prepare and prove CNC machine tool programs | 3.1 | Describe the safe working practices and procedures to be followed when developing and proving CNC machine tool programs |
| 3.2 | Describe the hazards associated with using CNC machine tools (such as automatic machine operations, power operated chucks, revolving/moving parts of machinery, airborne and hot metal particles, sharp cutting tools and burrs and sharp edges on component), and how they can be minimised |
| 3.3 | Describe the importance of wearing the appropriate protective clothing and equipment, and of keeping the work area clean and tidy |
| 3.4 | Describe the safety mechanisms on the machine (such as emergency stop buttons, emergency brakes), and the procedure for checking that they function correctly |
| 3.5 | Describe the correct operation of the various hand and automatic modes of machine control (such as handwheels, joysticks, program operating and control buttons) |
| 3.6 | Explain how to stop the machine in both normal and emergency situations, and the procedure for restarting after an emergency |
| 3.7 | Explain how to use and extract information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS or ISO standards) in relation to work undertaken |
| 3.8 | Explain how to interpret first and third angle drawings, imperial and metric systems of measurement, absolute and incremental systems, workpiece zero/reference points and system of tolerancing |
| 3.9 | Describe the computer coding language used in CNC programs (with regard to machine axes, positional information, machine management and auxiliary functions) |
| 3.10 | Explain how to prepare part programs (using operational sequences and machining techniques that avoid unnecessary tool/cutter movements or tool changes) |
| 3.11 | Describe the use of features that enable reductions in program size and input time (such as canned cycles, subroutines and labels) |
| 3.12 | Describe the function keys and operating system of the machine computer control system being operated |
| 4 | 2b. Know how to prepare and prove CNC machine tool programs (continued) | 4.1 | Explain how to set machine datums for each of the machine axes being used |
| 4.2 | Explain how to set the machine control system in the programming and editing mode, download (input) and upload (output) modes |
| 4.3 | Explain how to deal with error messages and faults on the program or equipment |
| 4.4 | Explain how to access the program edit facility, in order to enter tooling data (such as tool datums, positions, lengths, offsets and radius compensation) |
| 4.5 | Describe the use of tool posts, magazines, carousels and turrets, and how to identify the tools in relationship to the operating program |
| 4.6 | Explain how to conduct trial runs (using single block run, dry run and feed and spindle speed override controls) |
| 4.7 | Describe the factors that may affect the feeds and spindle speeds being used, and why they may need to be adjusted from the programmed values (such as condition of material, workholding method, tooling used, tolerance and finish to be achieved) |
| 4.8 | Describe the checks to be made before allowing the CNC machine to operate in full program run mode |
| 4.9 | Explain how to save the completed programs in the appropriate format, and the need to store program tapes and disks safely and correctly, away from contaminants and electromagnetic sources |
| 4.10 | Describe the typical problems that can occur with the programming, loading and editing activities, and what to do if they occur |
| 4.11 | Explain when to act on their own initiative and when to seek help and advice from others |
| 4.12 | Describe the importance of leaving the work area and machine in a safe condition on completion of the activities (such as correctly isolated, operating programs closed or removed, cleaning the machine and removing and disposing of waste) |
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