View Unit : Assembling Cores using Jigs and Fixtures

Unit

Unit Reference Number

Y/502/9202

Qualification Framework

QCF

Title

Assembling Cores using Jigs and Fixtures

Unit Level

Level 3

Unit Sub Level

None

Guided Learning Hours

Unit Credit Value

Date of Withdrawal

SSAs

4.1 Engineering

Unit Grading Structure

Pass

Assessment Guidance

This unit must be assessed in a work environment and must be assessed in accordance with the ‘Common Requirements for National Vocational Qualifications (NVQ) in the QCF’ which can be downloaded from Semta’s website: http://www.semta.org.uk/training_providers__awarding/national_occupational_standard/qca_assessment_requirements.aspx

Additional assessment requirements have been published by Semta. These additional assessment requirements are set down in Semta’s Engineering assessment strategy which can be downloaded from Semta’s website: http://www.semta.org.uk/training_providers__awarding/national_occupational_standard/qca_assessment_requirements.aspx

View Unit's Qualifications

Learning Outcomes and Assessment Criteria

Learning Outcome - The learner will:		Assessment Criterion - The learner can:
1	Assemble Cores using Jigs and Fixtures	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 assembly and closing activities: confirm that the cores received are complete and free from defects check that the work area is clear of obstructions and hazards use appropriate personal protective equipment comply with job instructions, core assembly specifications, relevant COSHH sheets and risk assessment documentation use the correct tools and equipment for the core assembly and preparation activities follow the defined core assembly and preparation procedures, and apply safe working practices and procedures at all times ensure that the completed core assembly meets the required specification for quality and accuracy leave the work area in a safe condition on completion of the core assembly activities
		1.3	Follow the relevant instructions, assembly drawings and any other specifications
		1.4	Ensure that the specified components are available and that they are in a usable condition
		1.5	Use the appropriate methods and techniques to assemble the components in their correct positions
		1.6	Assemble cores to form sub-assemblies, using two of the following: freehand manual methods jigs fixtures combined methods
		1.7	Assemble cores produced from one of the following sands: chemically bonded gas activated chemically bonded resin catalyst oil sand ester silicate bonded resin bonded heat activated
		1.8	Apply mould coatings, as appropriate, using one of the following methods: brush spray flood
		1.9	Assemble the cores using both of the following methods: manual means mechanical means
		1.10	Determine cast metal thickness, using two of the following methods: direct measurement clay slugs gauges templates jigs fixtures
		1.11	Assemble a minimum of three cores per assembly, using two of the following location devices: pins rebates prints diabolos set-offs joining cores dovetails other specific method
		1.12	Secure the components using the specified connectors and securing devices
		1.13	Secure the cores together to form complete moulds, using two of the following methods: print locations adhesives studs or chaplets wire (tied down or back) pins interlocking cores fixtures
		1.14	Maintain metal thickness between the assembled cores, using one of the following methods: polystyrene studs or chaplets other specific method
		1.15	Seal and protect the core vents, where appropriate, using one of the following materials: adhesive flexible mastic sand plumbago and oil
		1.16	Check the completed assembly to ensure that all operations have been completed and the finished assembly meets the required specification
		1.17	Deal promptly and effectively with problems within their control and report those that cannot be solved
2	Know how to Assemble Cores using Jigs and Fixtures	2.1	Describe the hazards and specific safety precautions to be taken when assembling cores to form sub-assemblies manually and with mechanical assistance
		2.2	Describe the hazards associated with the use of mechanical equipment in the handling of cores and core sub-assemblies
		2.3	Describe the COSHH regulations that apply when dealing with resin bonded sands, solvents, adhesives, and core dressings
		2.4	Describe where to obtain information on COSHH regulations
		2.5	Explain the Provision and Use of Work Equipment Regulations (PUWER)
		2.6	Describe the manual lifting techniques, and EU requirements on acceptable weights to be handled
		2.7	Describe what personal protective equipment (PPE) should be used, and how to obtain it
		2.8	Describe how to obtain the necessary job instructions and interpret the information
		2.9	Explain the procedure to be followed in the event of equipment or machine malfunction
		2.10	Explain why it is necessary to check the cores prior to commencing the assembly operations
		2.11	Describe the defects that can occur in the cores (such as cracked surfaces, exposed reinforcements, friable surfaces, broken or weak core sections, incomplete cores, damaged or broken core prints and core locations, uncoated cores)
		2.12	Describe the actions that are needed when cores are found to be sub-standard
		2.13	Describe the storage requirements of cores produced from various types of sands
		2.14	Describe the differences in assembly methods using manual freehand, jigs, fixtures and combined methods
		2.15	Describe the different processes and machines used to make the cores
		2.16	Explain why and how metal thickness checks are made (using such things as direct measurement, clay slugs, gauges, templates, jigs and fixtures)
		2.17	Explain why different core location devices are used during the assembly activities (such as pins, rebates, prints, diabolos, set-offs, joining cores and dovetails)
		2.18	Explain why different methods are used to secure the cores to form sub-assemblies (such as print locations, adhesives, studs or chaplets, wire ties, pins, interlocking cores and fixtures)
		2.19	Explain why cores in the sub-assemblies are held in place prior to inserting them into the mould cavity (using such things as polystyrene, studs or chaplets)
		2.20	Describe the effects on casting quality and accuracy of incorrectly located and secured cores
		2.21	Explain why different types of securing devices are used on ferrous and non-ferrous alloys
		2.22	Explain why different methods of securing cores in moulds are used when castings are required to be pressure tight or have other operational requirements
		2.23	Explain why it is important to keep the equipment clean and free from damage, to practice good housekeeping of tools and equipment, and to maintain a clean working area
		2.24	Describe the extent of their own authority and whom they should report to if they have problems that they cannot solve when assembling the cores to form complete moulds

Equivalent Units

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