| 1 | 1a. Set CNC vertical boring 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 during the setting-up activities: • 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 • confirm that the correct operating program has been loaded • check that the tooling is in a usable condition • ensure that the workpiece is correctly positioned and secured without distortion • update the program tool data as applicable • ensure that correctly adjusted machine guards are in place • 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: • dimensional tolerance equivalent to BS4500 or BS 1916 Grade 7 • surface finish 63µin or |
| 1.5 | µm • reamed and bored holes within H8 • flatness and squareness |
| 1.6 | ” per inch or |
| 1.7 | mm per 25mm • angles within +/- |
| 1.8 | degree • screw threads BS medium fit |
| 1.9 | Determine what has to be done and how the machine will be set to achieve this |
| 1.10 | Prepare one of the following CNC boring machines in readiness for production: • CNC vertical boring machine • CNC boring centre |
| 1.11 | Prepare the tooling for operation by carrying out all of the following activities, as applicable to the machine type: • positioning tools in the correct position in the tool posts, turrets, magazine or carousel • checking tools have a specific tool number in relation to the operating program • entering all relevant tool data to the operating program (such as tool lengths, tool offsets, radius compensation) • pre-setting tooling using setting jigs/fixtures • setting tool datum’s • saving changes to programme |
| 1.12 | Mount and set the required workholding devices, workpiece and cutting tools |
| 2 | 1b. Set CNC vertical boring machines for production (continued) | 2.1 | Position and secure workpieces using four of the following workholding methods and devices: • clamping direct to machine table • machine vice (such as plain, swivel, universal) • three jaw chucks, hard jaws • pneumatic or magnetic table • indexing/rotating device • vee block and clamps • three jaw chucks, soft jaws • angle plate • other workholding devices • four jaw chucks • fixtures |
| 2.2 | Select and mount, in the appropriate tool holding device, eight of the following types of cutting tool: • boring bars • turning tools • chamfering tools • recessing tools • profiling • form tools • centre drills • twist/core drills • boring tools • reamers • grinding wheels • milling cutters |
| 2.3 | Set the machine tool operating parameters to achieve the component specification |
| 2.4 | Set up the machine to produce components, combining several different operations, and cover ten of the following: • plain internal/external diameters • stepped diameters • tapered diameters • special forms (such as concave, convex) • angular faces • internal/external undercuts • internal and external profiles • drilled holes • reamed holes • tapped holes • eccentric diameters • screw threads • internal bores • chamfers and radii • bored holes • flat faces |
| 2.5 | Machine one of the following types of material: • ferrous • non-ferrous • stainless • non-metallic |
| 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 CNC vertical boring machines for production | 3.1 | Describe the specific safety precautions to be taken when setting up workholding devices and tooling on CNC vertical boring machines |
| 3.2 | Explain how to start and stop the machine in normal and emergency situations |
| 3.3 | Describe the importance of ensuring that the machine is isolated from the power supply before mounting cutting tools and workholding devices |
| 3.4 | Describe the importance of wearing the appropriate protective clothing and equipment, and of keeping the work area clean and tidy |
| 3.5 | Describe the hazards associated with working on CNC vertical boring machines (such as use of moving machinery, automatic machine operation, handling cutting tools, lifting and handling workholding devices, hot and airborne metal particles), and how to minimise them and reduce any risks |
| 3.6 | Explain how to handle and store cutting tools and verified tapes and programs, 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 range of workholding methods and devices that are used on CNC vertical boring machines |
| 3.10 | Explain why it is important to set the workholding device in relation to the machine datums and reference points |
| 3.11 | Describe the methods of setting the workholding devices, and the tools and equipment that can be used |
| 3.12 | Describe the range of cutting tools that are used on CNC vertical boring machines, and typical applications |
| 4 | 2b. Know how to set CNC vertical boring machines for production (continued) | 4.1 | Explain how to check that the cutting tools are in a safe and serviceable condition |
| 4.2 | Describe the use of tungsten carbide, ceramic and diamond indexible tips, and the factors which will determine their selection and use (such as the condition of material supplied, hardness of the material, the cutting characteristics of the material, tolerances to be achieved, component surface finish and specifications) |
| 4.3 | Describe the various tool holding devices that are used, and the methods of correctly mounting and securing the cutting tools to the tool holders |
| 4.4 | Describe the advantages of using pre-set tooling, and how to set the tooling using setting jigs/fixtures |
| 4.5 | Describe the use of tool posts, magazines and carousels, and how to position and identify the tools in relation to the operating program |
| 4.6 | Explain how to place the machine into the correct operating mode, and how to access the program edit facility in order to enter tooling data (such as tool datums, positions, lengths, offsets and radius compensation) |
| 4.7 | Explain how to conduct trial runs, using single block run, dry run and feed/speed override controls |
| 4.8 | Describe the things that they need to check before allowing the machine to operate in full program run mode |
| 4.9 | Explain how the various types of materials will affect the feeds and speeds that can be used |
| 4.10 | 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 |
| 4.11 | Describe the typical problems that can occur with the setting up of the tooling and workholding devices, and what to do if they occur |
| 4.12 | 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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