| 1 | 1a. Set capstan and turret lathes 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 • ensure that correctly adjusted machine guards are in place • check that cutting tools are in a suitable condition • hold components securely without distortion • 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 up machine in accordance with instructions and specifications, to include setting all of the following: • position of workpiece in work holding device • position of turning tools in relationship to workpiece • screw threading devices • workpiece speed and feed • depth of cut for roughing and finishing • turret and saddle feed stops and indicators • cutting fluid flow rate • machine guards/safety mechanisms |
| 1.5 | Determine what has to be done and how the machine will be set to achieve this |
| 1.6 | Mount and set the required workholding devices, workpiece and cutting tools |
| 1.7 | Select, mount and secure the workpiece using four of the following workholding devices: • hand chucks with hard jaws • hand chucks with soft jaws • power chucks with hard jaws • power chucks with soft jaws • jigs/fixtures • collet chucks |
| 1.8 | Use two of the following groups of turning tools: • solid high-speed steel • brazed tungsten carbide • indexible tips (carbide, ceramic, diamond) |
| 2 | 1b. Set capstan and turret lathes for production (continued) | 2.1 | Select and mount roughing and finishing tools, to include eight of the following types of tools: • turning tools • facing tools • form tools • chamfer/radius • parting off tools • thread chaser • single point threading • boring bars • recessing tools • centre drills • twist/core drills • solid reamers • expanding reamers • taps • dies • knurling tools |
| 2.2 | Mount, secure and position tools in all of the following: • front tool box • rear tool post • ending boxes • die boxes • roller box • polygon/special profile boxes • turret/capstan knee box • boring bars (single / multiple) • chucks/floating arrangements • multiple cutting arrangements |
| 2.3 | Set the machine tool operating parameters to achieve the component specification |
| 2.4 | Set up the machine to produce internal and external profiles that include ten of the following: • flat faces • parallel diameters • stepped diameters • tapered diameters • drilled holes • bored holes • reamed holes • profile forms • internal threads • external threads • eccentric features • parting off • chamfers and radii • knurls/special finishes • grooves/undercuts • counterbores |
| 2.5 | Machine components from one of the following types of material: • ferrous • non-ferrous • non-metallic |
| 2.6 | Set the machine to produce components within all of the following quality and accuracy standards, as applicable to the operations performed: • components to be free from false tool cuts, burrs and sharp edges • dimensional tolerance equivalent to BS 4500 or BS 1916 Grade 7 • reamed and bored holes within H8 • screw threads BS medium fit • angles within +/- |
| 2.7 | degree • surface finish 63µin or |
| 2.8 | µm |
| 2.9 | Check that all safety mechanisms are in place and that the equipment is set correctly for the required operations |
| 2.10 | Deal promptly and effectively with problems within their control and report those that cannot be solved |
| 3 | 2a. Know how to set capstan and turret lathes for production | 3.1 | Describe the specific safety precautions to be taken when setting up workholding devices and accessories, workpiece and turning tools on capstan and turret lathes |
| 3.2 | Describe the hazards associated with setting capstan and turret lathes (moving parts of machinery, handling turning tools, handling cutting fluids, airborne particles, tool breakage, power chucks and power bar feed arrangements, insecure components), and how they can be minimised and reduce any risks |
| 3.3 | Explain how to start and stop the machine in normal and emergency situations |
| 3.4 | Describe the importance of ensuring that the machine is isolated from the power supply before mounting turning tools and workholding devices |
| 3.5 | Describe the importance of wearing the appropriate protective clothing and equipment, and of keeping the work area clean and tidy |
| 3.6 | Describe the basic principles of operation of the capstan or turret lathe and its accessories, and typical operations that they can perform |
| 3.7 | Explain how to handle and store turning tools safely and correctly |
| 3.8 | 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 |
| 3.9 | Explain how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing |
| 3.10 | Describe the terminology used in capstan and turret lathe turning in relation to the activities undertaken |
| 3.11 | Describe the range of workholding methods and devices that are used on capstan and turret lathes (such as two three and four jaw chucks, hand and power operated chucks, power bar feed arrangements, collet chucks, jigs and fixtures) |
| 4 | 2b. Know how to set capstan and turret lathes for production (continued) | 4.1 | Describe the use of hard and soft jaws in chucks, and the methods of boring out soft jaws to suit the workpiece |
| 4.2 | Describe the different types of turning tools that are used, and how they are selected, prepared and mounted to the machine tool holding devices (such as front tool box, rear tool box, capstan/turret head, roller boxes, ending boxes, special profiling boxes, die boxes) |
| 4.3 | Describe the use of pilot bars and shoes for the capstan/turret, and why they need to be accurately aligned |
| 4.4 | Explain the need to produce a balanced capstan/turret arrangement, with tools appropriately positioned around the turret stations |
| 4.5 | Describe the factors which determine speeds and feeds to be used (such as material, type of tooling, depth of cut, workpiece rigidity, machine condition, multiple cutting arrangements between capstan/turret and saddle, tolerance and finish required) |
| 4.6 | Explain how the various types of material will affect the feeds and speeds that can be used |
| 4.7 | Describe the types of cutting fluid that are used, and precautions to be taken when handling and using them |
| 4.8 | Explain how to set up the turret lathe and its accessories for the particular operations being performed |
| 4.9 | Explain the need to conduct trial runs, and to check that the machine is set up and producing the components correctly |
| 4.10 | Describe the problems that can occur with setting up the workholding devices, tooling and machine operating parameters, and what to do if they occur |
| 4.11 | 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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