COMPETENCY ANALYSIS PROFILE MOULD MAKER 431A (All unshaded skill sets must be demonstrated/completed)
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1 COMPETENCY ANALYSIS PROFILE MOULD MAKER 431A (All unshaded skill sets must be demonstrated/completed) SKILL SETS SKILLS PROTECT SELF AND OTHERS Identify health and safety hazards in the workplace. Wear, adjust, and maintain personal protective Wear, adjust, and maintain respiratory protectors. Practise safe work habits. Check tapers Operate emergency safety Practise industrial hygiene in the workplace Conduct preoperational check of Report injuries Follow procedures for applying first aid Lock out mechanical Handle designated substances Operate lifting Follow hot-runner safe testing procedures PLAN AND PREPARE FOR MACHINING JOB Read and interpret engineering drawings. Perform calculations for machining operations. Read and interpret workprocess. Verify workpiece material. cutting fluids machines check machine controls and systems select tooling prepare cutting measuring instruments and checking devices Select machine speeds and feeds Lay out features of engineering drawings select workholding devices Pick up datum/starting lifting and rigging Communicate with co-workers
2 WORK-IN- PROCESS DIMENSIONAL OR SURFACE VERIFICATION Check straight cuts. Check shapes. Check threads. Check holes. Check tapers Check hardness Deburr Check surfaces BENCHWORK Hand-file. Hand-saw. Hand-drill holes. Hand-tap threaded holes. Hand-ream Chase threads Hand-grind
3 SAWING Check fused/welded blade. Lay out features of engineering drawings. workpiece in saw. feeds of saw. Install and test-run blade Check first cut-off Cut shapes using a vertical bandsaw Cut squared and angled surfaces using a power cut-off saw Deburr Move workpiece DRILLING USING DRILL PRESS/ MACHINE Select drill tooling. prepare cutting tools for drills. workpiece in drill. Set up tooling in drills. feeds of drill Centre-drill a layout punch mark Drill a hole Chamfer a hole Ream a hole Machine-thread a hole Spot-face a hole Counter-bore a hole Counter-sink a hole Deburr Move
4 MACHINE GRINDING Select grinding wheel. Check condition of grinding wheel. Install grinding wheel. workpiece in grinder. Surface grind Hone holes Lap workpiece Grind inside and outside diameters. (ID/OD) Grind tools and cutters Check ground surfaces Move LATHE WORK Select lathe cutting prepare lathe workpiece in lathe. Set up lathe feeds of lathe Take a sizing (preliminary) cut Establish a reference or starting point.(datum) Face a surface Turn an external diameter Drill a hole Bore an internal diameter Ream a hole Tap a hole Turn an internal or external thread Produce a taper Knurl cylindrical surface patterns Groove and part-off Deburr Move workpiece
5 MILLING Select milling prepare milling Set-up and maintain milling adjustable support Set-up milling feeds of mill Perform fly-cutting. Face-mill Machine steps, cut-outs, angles, and open slots Machine a pocket or slots Machine a hole Bore holes Deburr Move NC/CNC MACHINING NC/CNC machining process. Identify, select, & set up NC /CNC cutting tools and tool holders. Identify, select, and set machine parameters. Position and align workpiece in NC/CNC machine. Input and verify part program at NC/CNC machine controls Verify tool sequence, tool path, & collision avoidance program. Monitor NC/CNC machining process. Make adjustments to tooling and offsets inspection Move
6 ELECTRICAL DISCHARGE MACHINING (EDM) EDM process Develop EDM electrodes. Identify, select, and set up EDM machining Identify, select, and set machine parameters. Position, align, and secure workpiece in EDM machine Input and verify part program to the EDM machine controls Cut workpiece by EDM machining Move workpiece DEVISE AND DETAIL A PLAN FOR THE MOULD- BUILDING PROCESS Verify features of the mould Build tooling aids for mould-building process. Develop and organize a mouldbuild plan Lay out template(s). Perform mouldbuilding related calculations. Produce templates Assemble and verify tooling stock materials Produce a detailed sketch of mould
7 BUILD/ FABRICATE MOULD COMPONENTS Rough-out mould components Stabilize workpiece material. Produce cores. Produce lifters, inserts, and slides. Produce cavities Produce detailed parts Move FIT AND ASSEMBLE A MOULD Transfer and locate holes. Fit and size mould Check cooling and heating circuits. Install mould components in the spotting press. Spot the mould Final-inspect mould Install ejector system Install runner system Check assembled mould Move FINISH/POLISH THE MOULDING SURFACE hand-finishing Clean and deburr mould surface. Detail the Remove tool and cutter marks. Verify contours of the Final-finish the mould surface Move workpiece
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