The National Institute for Metalworking Skills, Inc. Duties and Standards For Machining Skills-Level III NIMS/ANSI 101-2001 Developed By: Copyright July 1997-Revised September 2001 Distributed by: The National Institute for Metalworking Skills, Inc 3251 Old Lee Highway Fairfax, VA 22030 1-703-352-4971 Fax 1-703-352-4991 www.nims-skills.org
Duties and Standards for Machining Skills--Level III i.
Table of Contents Occupational Description and Benchmarks... 3 Occupational Description... 3 Bench Skills... 3 Metal Cutting Skills...3 Inspection and Quality Assurance Skills... 3 Other Skills and Competencies... 4 Framework for Machining Skills Level III... 5 Duty Area: 1. Job Planning and Management... 7 Duty: 1.1 Job Process Planning... 7 Duty Area: 2. Job Execution... 9 Duty: 2.1 Bench Operations: Hand Lapping... 9 Duty: 2.2 Angle Contour Bandsawing... 11 Duty: 2.3 Turning Operations: Manual Contour Turning... 13 Duty: 2.4 Turning Operations: Steady Rest Turning and Boring... 15 Duty: 2.5 Turning Operations: Follower Rest Turning... 17 Duty: 2.6 Turning Operations: Difficult Materials... 19 Duty: 2.7 Milling: Mill Compound Angles... 21 Duty: 2.8 Milling: Manual Contour Milling... 23 Duty: 2.9 Horizontal Boring Mill: Line Boring... 25 Duty: 2.10a Grinding: Select, Inspect, Set up, and Balance Wheels... 27 Duty: 2.10b Grinding: Tapered Cylindrical Grinding... 29 Duty: 2.11 Grinding: Grind I.D. and O.D. Surfaces... 31 Duty: 2.12 Grinding: Grind Tapers on an Universal Grinder... 33 Duty: 2.13 Grinding: Contour Grinding... 35 Duty: 2.14 EDM: Operate a 4 Axis Wire EDM... 37 Duty: 2.15 CNC: Advanced Manual RS-274-D Programming... 39 Duty: 2.16 CNC: Use Manufacturing Modeling Software to Create RS-274-D Programs... 41 Duty: 2.17 CNC: Milling Centers... 43 Duty: 2.18 CNC: Turning Centers... 45 Duty: 2.19 CNC: Turning Centers with Secondary Milling... 47 Knowledge, Skills, Abilities and Other Characteristics KSAO Area: 2. Mathematics... 49 KSAO: 2.1 Geometry of Compound Angles, Profiles of a Line, and Profile of a Surface... 49 KSAO Area: 3. Computer Aided Manufacturing Technology... 50
KSAO:3.1 Computer Aided Manufacturing Software... 50 APPENDIX A Cross-References to Machining Skills Level I & II... 51 Cross-References to Machining Skills Level I KSAO Area: 1. Written and Oral Communication... 52 KSAO: 1.1 Reading... 52 KSAO: 1.2 Writing... 54 KSAO: 1.3 Speaking... 56 KSAO: 1.4 Listening... 58 KSAO Area: 3. Decision Making and Problem Solving... 60 KSAO: 3.1 Applying Decision Rules... 60 KSAO: 3.2 Basic Problem Solving... 62 KSAO Area: 4. Group Skills and Personal Qualities... 63 KSAO: 4.1 Group Skills... 63 KSAO: 4.2 Personal Qualities... 65 Cross-References to Machining Skills Level II KSAO Area: 3. Engineering Drawings and Sketches... 66 KSAO: 3.1 Isometric and Orthographic Sketching... 66 KSAO: 3.2 Interpreting Engineering Drawings: Geometric Dimensioning and Tolerancing...... 67 KSAO: 3.3 Interpreting Engineering Drawings: Auxiliary Views... 68 KSAO Area: 4. Measurement... 69 KSAO: 4.1 Manual Coordinate Measuring Machines... 69 APPENDIX A National Institute for Metalworking Skills, Inc-Executive Committee... 70 APPENDIX B National Institute for Metalworking Skills, Inc. Board of Directors... 71 2
Machining Skills Level III Occupational Description and Benchmarks for Machining Skills Level III Occupational Description Machining Skills Level III are used by skilled tradespersons who have achieved proficiency in the core competencies of Machining Skills I and II and have advanced to higher levels of technical competency or have developed new competencies. The general areas of competency remain: Bench skills Metal cutting skills Inspection and quality assurance skills Machining Skills Level III applies to both single part and multiple part production. A person who has achieved Machining Skills III competency may have modest supervision responsibilities for other operators or production workers. Additionally, people who have achieved Skills III competence will be called upon to provide training for machining technicians. Bench skills Lay out of hole locations on bolt circles, angular surfaces, profiles of a line and points of tangency. Read and comprehend complex orthographic blueprints using geometric dimensioning and tolerancing symbology. Read and comprehend blueprints that have multiple auxiliary views. Hand lap small surfaces. Metal cutting skills: Use indexing devices to locate part features. Produce compound angled and irregular surfaces. Produce work to close tolerances. Set up and operate a boring mill. Set up and operate a cylindrical grinder. Set up and operate CNC machine tools. Improve setups on common classes of machine tools. Gain competence in all safety procedures for all tasks within the scope of Machining Skills Level III. Select and use cutting fluids. Inspection and quality assurance skills: Develop and document inspection procedures for in-process inspection. Inspect compound angles to required precision. Develop inspection process plans. Use visual comparator for inspection tasks. Use gage blocks for shop calibration of precision tools. 3
Other skills and competencies: Write CNC programs requiring multiple tools, planes, canned cycles, and offsets. Qualify tools for CNC use. Participate effectively as a member of a team. Maintain employment in the metalworking industry. Articulate a personal career development plan within the metalworking industry. Produce process plans which identify operations, sequence, tools, fixtures, speeds and feeds for parts requiring several of the basic machining operations such as milling, drilling, turning, or grinding. Record work activities. Write required work reports. Succeed in interactive verbal and written communication. Train others as assigned. Perform supervisory duties. 4
Machining Skills Level III Duty and Skills Standards Table The left-hand column is a list of activities performed on the job. The right-hand column is a list of the abilities, skills, knowledge, or other characteristics that are needed to perform the duties. Occupational Duties Knowledge, Skills, Abilities, and Other Characteristics 1. Job Planning and Management 1.1 Job Process Planning 2. Job Execution 2.1 Bench Operations: Hand Lapping 2.2 Angle Contour Bandsawing 2.3 Turning Operations: Manual Contour Turning 2.4 Turning Operations: Steady Rest Turning & Boring 2.5 Turning Operations: Follower Rest Turning 2.6 Turning Operations: Difficult Materials 2.7 Milling: Mill Compound Angles 2.8 Milling: Manual Contour Milling 2.9 Horizontal Boring Mill: Line Boring 2.10a Grinding: Select, Inspect, Set up, & Balance Wheels 2.10b Grinding: Tapered Cylindrical Grinding 2.11 Grinding: Grind I.D. and O.D. Surfaces 2.12 Grinding: Grind Tapers on an Universal Grinder 2.13 Grinding: Contour Grinding 2.14 EDM: Operate a 4 Axis Wire EDM 2.15 CNC: Advanced Manual RS-274-D Programming 2.16 CNC: Use Manufacturing Modeling Software to Create RS-274-D Programs 2.17 CNC: Milling Centers 2.18 CNC: Turning Centers 2.19 CNC: Turning Centers with Secondary Milling 3. Quality Control and Inspection 3.1 Part Inspection 3.2 Process Control 4. Process Adjustment and Control 4.1 Process Adjustment, Single Part Production 4.2 Participation in Process Improvement 5. General Maintenance 5.1 General Housekeeping and Maintenance 5.2 Preventive Maintenance 5.3 Tooling Maintenance 6. Industrial Safety and Environmental Protection 6.1 Machine Operations and Material Handling 6.2 Hazardous Materials Handling and Disposal 1. Written and Oral Communications 1.1 Reading 1.2 Writing 1.3 Speaking 1.4 Listening 2. Mathematics 2.1 Geometry of Compound Angles, Profiles of a Line and Profile of a Surface 3. Computer Aided Manufacturing Technology 3.1 Computer Aided Manufacturing Software 4. Decision Making and Problem Solving 4.1 Applying Decision Rules 4.2 Basic Problem Solving 5. Group Skills and Personal Qualities 5.1 Group Participation and Teamwork 5.2 Personal Qualities 6. Engineering Drawings and Sketches 6.1 Standard Orthographic Blueprints 6.2 GDT Orthographic Blueprints 5
7. Career Management and Employment Relations 7.1 Career Planning 7.2 Job Applications and Interviewing 7.3 Teamwork and Interpersonal Relations 7.4 Organizational Structures and Work Relations 7.5 Employment Relations 7. Measurement 7.1 Basic Measuring Instruments 7.2 Precision Measuring Instruments 7.3 Surface Plate Instruments 6
Machining Skills Level III Duty Area: 1. Job Planning and Management Duty Title: 1.1 Job Process Planning Duty: Write a detailed process plan that includes a quality plan for a part requiring milling, drilling, turning, or grinding. Produce an operation sheet detailing the process plan and required speeds and feeds. Provide sketches as needed. Performance Standard: Given a blueprint detailing a part requiring milling, drilling, turning, and grinding, verbal instructions, and appropriate references, formulate a set of strategies to manufacture the part and write a detailed process plan including a quality plan for that part. Provide sketches as needed. Make a presentation explaining each of the process plan steps to be taken, identify all major components and functions of the machine tools, and all major hand tools, measuring tools, tools and fixtures, work materials and provide the rationale for the speeds and feeds selected. Other Evaluation Criteria: 1. Legibility. 2. Clarity of the writing. 3. Appropriate speeds and feeds. Accuracy Level: N/A. Assessment Equipment and Material: Workstation: Standard workbench. Material: A blueprint with an appropriate part, an inventory of available tools, necessary writing materials. Tooling: N/A. Measuring Instruments: N/A. Reference: Machinery's Handbook. 7
KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Job Process Planning Duty. Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views X Writing X Orthographic Blueprints: GDT Multiple Datums X Speaking Isometric and Orthographic Sketching X Listening Measurements Mathematics Basic Measurements X Arithmetic Optical Comparator X Geometry of Simple Angles & Line Profiles Manual Coordinate Measuring Machine X Coordinate Axes, Cartesian & Polar Metalworking Theory X Trigonometry for CNC Toolpaths X Cutting Theory Statistics for Capability Studies X CNC Tooling Decision Making and Problem Solving X Metal Properties & Cutting X Applying Decision X Non-metal Properties & Cutting X Basic Problem Solving X CNC Machine Tools Group Skills and Personal Qualities X Cutting Fluids and Coolants for Specific Jobs Group Participation Personal Qualities Electrode Design and Selection Computers Typing Services of an Operating System 8
Machining Skills Level III Duty Area: 2. Job Execution Duty Title: 2.1 Bench Operations: Hand Lapping Duty: Hand lap small surfaces to finish. Performance Standard: Given a blueprint, access to a lapping plate, an appropriate ground part, lapping compound, and cleaning solutions, lap a surface to flatness and finish requirements. Accuracy Level:.0001 flatness over 4" square surface, 8 microinch surface finish. Assessment Equipment and Material: Workstation: Standard workbench with a lapping plate that can be fixed in place. Material: A part ground to the lapping blueprint, material: 1215 CRS. Lapping compound and cleaning solution, with appropriate disposal for both.. Tooling: Wipes. Measuring Instruments: Optical flats, indicators, electronic gages, laboratory grade surface plate, transfer gage. Reference: Machinery's Handbook. 9
KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Bench Operations Duty of Hand Lapping. Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Listening Isometric and Orthographic Sketching Measurements Mathematics X Basic Measurements X Arithmetic Optical Comparator Geometry of Compound Angles Manual Coordinate Measuring Machine X Geometry of Profiles of a Surface Metalworking Theory Coordinate Axes, Cartesian & Polar Trigonometry for CNC Toolpaths Cutting Theory CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving Non-metal Properties & Cutting X Applying Decision CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Group Participation Personal Qualities Electrode Design and Selection Computers Typing Services of an Operating System 10
Machining Skills Level III Duty Area: 2. Job Execution Duty Title: 2.1 Angle Contour Bandsawing Duty: Set up and perform contour sawing to a layout that requires the part to be sawed at angles with respect to the top and/or bottom. Choose and mount appropriate blades. Weld, break, and reweld blades as necessary. Performance Standard: Given a part with a finished layout and access to an appropriate bandsaw and blades, finish saw the part to the layout maintaining the required angular relationships of the finish with respect to the top and/or bottom. Accuracy Level: +/- 1/32 on all fractions, unless otherwise specified on the blueprint. Assessment Equipment and Material: Workstation: Standard workbench and an appropriate bandsaw. Material: A part matching the bandsaw blueprint, material: 1215 CRS. Tooling: A scriber, layout ink, prick punch, ball peen hammer, angle plate, C-clamps, magnifying glass. Measuring Instruments: Combination set, radius gages, 6" dividers, surface gage, or layout height gage. Reference: Machinery's Handbook. 11
KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Angle Contour Bandsawing Duty. Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Listening Isometric and Orthographic Sketching Measurements Mathematics X Basic Measurements X Arithmetic Optical Comparator X Geometry of Compound Angles Manual Coordinate Measuring Machine Geometry of Profiles of a Surface Coordinate Axes, Cartesian & Polar Trigonometry for CNC Toolpaths Metalworking Theory Cutting Theory CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving X Non-metal Properties & Cutting X Applying Decision CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Group Participation Personal Qualities Electrode Design and Selection Computers Typing Services of an Operating System 12
Machining Skills Level III Duty Area: 2. Job Execution Duty Title: 2.3 Turning Operations: Manual Contour Turning Duty: Set up and perform contour turning using tapers and form tools as necessary. Performance Standard: Given raw material, blueprint, hand, precision, and cutting tools, as well as access to an appropriate turning machine and its accessories, produce a part matching the process plan and the blueprint specifications using appropriate trade techniques and speeds and feeds. The part specified should have at least two diameters composed of a taper and two tangent radii. Accuracy Level: +/-.015 on all fractions, +/-.005 on all decimals unless otherwise specified on the blueprint. Diameters to be concentric within.001 T.I.R. Assessment Equipment and Material: Workstation: A standard workbench, a toolroom engine lathe, a three-jaw universal scroll chuck, and a four-jaw independent chuck. The lathe may have a quick-change gear box with the threads called for on the blueprint available from the gear box. A pedestal grinding machine to offhand grind form tools. Material: A part matching the material requirements of the turning blueprint, material: 1215 CRS. Tooling: Tool post, right- and left-hand turning tools capable of turning to a square shoulder, a drill chuck, centerdrill, external undercut tools, 45 o chamfer tools, assorted tool blanks for form tools, live center, dead center fitted to the spindle taper, magnetic base for a dial indicator, files, wrenches as necessary. Measuring Instruments: Required micrometers, combination set, dial indicator, 6" rule, a 6" vernier, dial, or electronic caliper, surface finish comparison plates, optical comparator, appropriate taper ring gages and Prussian blue, or taper micrometer, or sine bar and indicator. Reference: Machinery's Handbook. 13
KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Manual Contour Turning Operations Duty. Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Listening Isometric and Orthographic Sketching Measurements Mathematics X Basic Measurements X Arithmetic X Optical Comparator X Geometry of Compound Angles Manual Coordinate Measuring Machine Geometry of Profiles of a Surface Metalworking Theory Coordinate Axes, Cartesian & Polar X Cutting Theory Trigonometry for CNC Toolpaths CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving X Non-metal Properties & Cutting X Applying Decision CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Group Participation Personal Qualities Electrode Design and Selection Computers Typing Services of an Operating System 14
Machining Skills Level III Duty Area: 2. Job Execution Duty Title: 2.4 Turning Operations: Steady Rest Turning and Boring Duty: Set up and perform turning and boring operations requiring a steady rest. Performance Standard: Given raw material, blueprint, hand, precision, and cutting tools, as well as access to an appropriate turning machine and its accessories, produce a part matching the process plan and the blueprint specifications using appropriate trade techniques and speeds and feeds. The part specified will extend far enough from the spindle to require the support of a steady rest to facilitate boring on its ends. The part will have at least two bores within +/-.001, one UNC external thread, one UNF external thread, and will require the reversal of the part end for end. Accuracy Level: +/-.015 on all fractions, +/-.005 on all decimals unless otherwise specified on the blueprint. Diameters to be concentric within.001 T.I.R. Assessment Equipment and Material: Workstation: A standard workbench, a toolroom engine lathe, a steady rest, a three-jaw universal scroll chuck, and a four-jaw independent chuck. The lathe may have a quick change gear box with the threads called for on the blueprint available from the gear box. Material: A part matching the material requirements of the turning blueprint, material: 1215 CRS. Tooling: Tool post, right- and left-hand turning tools capable of turning to a square shoulder, an external threading tool matched to the profile of the thread called out on the turning blueprint, a drill chuck, centerdrill, external undercut tools, 45 o chamfer tools, live center, dead center fitted to the spindle taper, magnetic base for a dial indicator, files, wrenches as necessary and cutting fluids. Measuring Instruments: Required micrometers, combination set, thread pitch gages, center gage, pitch micrometer, thread ring and plug gages, dial indicator, 6" rule, a 6" vernier, dial, or electronic caliper, dial bore gages, surface finish comparison plates, and indicator. Reference: Machinery's Handbook. 15
KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Steady Rest Turning & Boring Operations Duty. Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Listening Isometric and Orthographic Sketching Measurements Mathematics X Basic Measurements X Arithmetic Optical Comparator Geometry of Compound Angles Geometry of Profiles of a Surface Manual Coordinate Measuring Machine Metalworking Theory Coordinate Axes, Cartesian & Polar X Cutting Theory Trigonometry for CNC Toolpaths CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving X Non-metal Properties & Cutting X Applying Decision CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Group Participation Personal Qualities Electrode Design and Selection Computers Typing Services of an Operating System 16
Machining Skills Level III Duty Area: 2. Job Execution Duty Title: 2.5 Turning Operations: Follower Rest Turning Duty: Set up and perform turning operations benefiting from the use of a follower rest. Performance Standard: Given raw material, blueprint, hand, precision, and cutting tools, as well as access to an appropriate turning machine and its accessories, produce a part matching the process plan and the blueprint specifications using appropriate trade techniques and speeds and feeds. The part specified will have at least three diameters within +/-.001, one of which will be an extended turn that will benefit from the use of a follower rest. Accuracy Level: +/-.015 on all fractions, +/-.005 on all decimals unless otherwise specified on the blueprint. Diameters to be concentric within.001 T.I.R. Assessment Equipment and Material: Workstation: A standard workbench, a toolroom engine lathe, a three-jaw universal scroll chuck, and a four-jaw independent chuck. Material: A part matching the material requirements of the turning blueprint, material: 1215 CRS. Tooling: Tool post, a follower rest, a steady rest, right- and left-hand turning tools capable of turning to a square shoulder, a drill chuck, centerdrill, drills, external undercut tools, 45 o chamfer tools, live center, dead center fitted to the spindle taper, magnetic base for a dial indicator, files, wrenches as necessary, and cutting fluids. Measuring Instruments: Required micrometers, combination set, dial indicator, 6" rule, a 6" vernier, dial, or electronic caliper, and surface finish comparison plates. Reference: Machinery's Handbook. 17
KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Follower Rest Turning Operations Duty. Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Listening Isometric and Orthographic Sketching Measurements Mathematics X Basic Measurements X Arithmetic Optical Comparator Geometry of Compound Angles Geometry of Profiles of a Surface Manual Coordinate Measuring Machine Metalworking Theory Coordinate Axes, Cartesian & Polar X Cutting Theory Trigonometry for CNC Toolpaths CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving X Non-metal Properties & Cutting X Applying Decision CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Group Participation Personal Qualities Electrode Design and Selection Computers Typing Services of an Operating System 18
Machining Skills Level III Duty Area: 2. Job Execution Duty Title: 2.6 Turning Operations: Difficult Materials Duty: Set up and perform turning refractory materials. Performance Standard: Given a 300 series stainless steel other than 303, blueprint, hand, precision, and cutting tools, as well as access to an appropriate turning machine and its accessories, produce a part matching the process plan and the blueprint specifications using appropriate trade techniques and speeds and feeds. The part specified should have at least two diameters within +/-.001, one UNC external thread, one UNF external thread. Accuracy Level: +/-.015 on all fractions, +/-.005 on all decimals unless otherwise specified on the blueprint. Diameters to be concentric within.001 T.I.R. Assessment Equipment and Material: Workstation: A standard workbench, a toolroom engine lathe, a three-jaw universal scroll chuck, and a four-jaw independent chuck. Material: 300 series stainless steel, except 303 Tooling: Tool post, right-and left-hand turning tools capable of turning to a square shoulder, an external threading tool matched to the profile of the thread called out on the turning blueprint, a drill chuck, centerdrill, drills, external undercut tools, 45 o chamfer tools, live center, magnetic base for a dial indicator, files, wrenches as necessary. Measuring Instruments: Required micrometers, combination set, thread pitch gages, center gage, pitch micrometer, thread ring gages, dial indicator, 6" rule, a 6" vernier, dial, or electronic caliper, and surface finish comparison plates. Reference: Machinery's Handbook. 19
KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Difficult Materials Turning Operations Duty. Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Listening Isometric and Orthographic Sketching Measurements Mathematics X Basic Measurements X Arithmetic Optical Comparator Geometry of Compound Angles Geometry of Profiles of a Surface Manual Coordinate Measuring Machine Metalworking Theory Coordinate Axes, Cartesian & Polar X Cutting Theory Trigonometry for CNC Toolpaths CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving Non-metal Properties & Cutting X Applying Decision CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Group Participation Personal Qualities Electrode Design and Selection Computers Typing Services of an Operating System 20
Machining Skills Level III Duty Area: 2. Job Execution Duty Title: 2.7 Milling: Mill Compound Angles Duty: Set up and mill flat surfaces at compound angles with respect to each other. Performance Standard: Given a previously squared-up block, blueprint, hand, precision, and cutting tools, a compound sine plate, or angle table, and access to an appropriate milling machine, mill compound angles. Inspect the angles using a sine bare or sine plate. Accuracy Level: +/-.015 on all fractions, +/-.002 on all decimals unless otherwise specified on the blueprint. Angles to +/-15' Assessment Equipment and Material: Workstation: A standard workbench, an appropriate milling machine. Material: A part matching the material requirements of the compound angle blueprint, material: 1215 CRS. Tooling: Required cutters and adapters, milling vise, toolmaker's vise, sine plates, tilting tables, clamps and studs, magnetic base for a dial indicator, files, wrenches as necessary. Measuring Instruments: Required micrometers, combination set, dial indicator, 6" rule, a 6" vernier, dial, or electronic caliper, bevel vernier protractor, tooling ball, precision pins, sine bar, sine plate, gage blocks, surface plate, and surface finish comparison plates. Reference: Machinery's Handbook, calculator with trigonometry functions. 21
KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Milling Compound Angles Duty. Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Listening Isometric and Orthographic Sketching Measurements Mathematics X Basic Measurements X Arithmetic Optical Comparator X Geometry of Compound Angles Manual Coordinate Measuring Machine Geometry of Profiles of a Surface Metalworking Theory Coordinate Axes, Cartesian & Polar X Cutting Theory Trigonometry for CNC Toolpaths CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving X Non-metal Properties & Cutting X Applying Decision CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Group Participation Personal Qualities Electrode Design and Selection Computers Typing Services of an Operating System 22
Machining Skills Level III Duty Area: 2. Job Execution Duty Title: 2.8 Milling: Manual Contour Milling Duty: Set up and mill curved surfaces through linear moves of varying lengths using methods of approximation from tapers, radii, interpolation, and sectioned templates. Performance Standard: Given a previously squared-up block, blueprint, hand, precision, and cutting tools, a compound sine plate, or angle table, other profiling accessories and access to an appropriate milling machine, mill surfaces which are composed of non-linear profiles. Accuracy Level: +/-.015 on all fractions, +/-.002 on all decimals unless otherwise specified on the blueprint. Angles to +/-30'. Assessment Equipment and Material: Workstation: A standard workbench, an appropriate milling machine. Material: A part matching the material requirements of the blueprint, material: 1215 CRS. Tooling: Required cutters and adapters, milling vise, toolmaker's vise, sine plates, tilting tables, template material, clamps and studs, magnetic base for a dial indicator, files, wrenches as necessary. Measuring Instruments: Required micrometers, combination set, dial indicator, 6" rule, a 6" vernier, dial, or electronic caliper, bevel vernier protractor, tooling ball, precision pins and surface finish comparison plates. Reference: Machinery's Handbook. 23
KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Manual Contour Milling Duty. Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Listening Isometric and Orthographic Sketching Measurements Mathematics X Basic Measurements X Arithmetic X Optical Comparator X Geometry of Compound Angles X Manual Coordinate Measuring Machine X Geometry of Profiles of a Surface Metalworking Theory Coordinate Axes, Cartesian & Polar X Cutting Theory Trigonometry for CNC Toolpaths CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving X Non-metal Properties & Cutting X Applying Decision CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Group Participation Personal Qualities Electrode Design and Selection Computers Typing Services of an Operating System 24
Machining Skills Level III Duty Area: 2. Job Execution Duty Title: 2.9 Horizontal Boring Mill: Line Boring Duty: Set up and bore a series of in-line concentric bores using line-boring techniques and the boring mill footstock. Performance Standard: Given a previously semi-finished part, blueprint, hand, precision, and cutting tools, and access to an appropriate boring mill, mill surfaces, diameters, and radii to match the blueprint. Accuracy Level: +/-.015 on all fractions, +/-.002 on all decimals unless otherwise specified on the blueprint. Angles to +/-15'. Assessment Equipment and Material: Workstation: A standard workbench, an appropriate milling machine. Material: A part matching the material requirements of the blueprint, material: 1215 CRS. Tooling: Required cutters and adapters, boring bars and single point boring tools, milling vise, a rotary table with power take off, clamps and studs, magnetic base for a dial indicator, files, wrenches as necessary. Measuring Instruments: Required micrometers, combination set, dial indicator, 6" rule, a 6" vernier, dial, or electronic caliper, dial bore gages, and surface finish comparison plates. Reference: Machinery's Handbook. 25
KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Horizontal Line Boring Duty. Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Listening Isometric and Orthographic Sketching Measurements Mathematics X Basic Measurements X Arithmetic Optical Comparator Geometry of Compound Angles Geometry of Profiles of a Surface Manual Coordinate Measuring Machine Metalworking Theory Coordinate Axes, Cartesian & Polar X Cutting Theory Trigonometry for CNC Toolpaths CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving X Non-metal Properties & Cutting X Applying Decision CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Group Participation Personal Qualities Electrode Design and Selection Computers Typing Services of an Operating System 26
Machining Skills Level III Duty Area: 2. Job Execution Duty Title: 2.10a Grinding: Select, Inspect, Set Up, and Balance Wheels Duty: Prepare grinding wheels for mounting in a cylindrical grinder or surface grinder. Mount the wheel and grind a 16 microinch finish on a surface. Dress as necessary. Performance Standard: Given a wheel and appropriate equipment prepare the wheel to go into service. Accuracy Level: N/A Assessment Equipment and Material: Workstation: A standard workbench and cylindrical grinder. Material: An appropriate grinding wheel. Tooling: Wheel balancer, counterweights, wheel arbor. Measuring Instruments:Dial test indicator, indicator mounting brackets Reference: Machinery's Handbook. 27
KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Grinding Duty to Select, Inspect, Set Up & Balance Wheels. Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Listening Isometric and Orthographic Sketching Measurements Mathematics X Basic Measurements X Arithmetic Optical Comparator Geometry of Compound Angles Geometry of Profiles of a Surface Manual Coordinate Measuring Machine Metalworking Theory Coordinate Axes, Cartesian & Polar X Cutting Theory Trigonometry for CNC Toolpaths CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving Non-metal Properties & Cutting X Applying Decision CNC Machine Tools X Basic Problem Solving Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Group Participation Personal Qualities Electrode Design and Selection Computers Typing Services of an Operating System 28
Machining Skills Level III Duty Area: 2. Job Execution Duty Title: 2.10b Grinding: Tapered Cylindrical Grinding Duty: Set up and grind tapers on a cylindrical grinder. Performance Standard: Given a part rough finished as a Morse taper, mount the part between centers and grind the required tapered diameter to finish. Dress the wheel as necessary. Accuracy Level: +/-.015 on fractions, +/-.005 on decimals, +/-.0002 on ground diameters. Assessment Equipment and Material: Workstation: A standard workbench and cylindrical grinder. Material: A part matching the material requirements of the cylindrical grinding blueprint, material: 1215 CRS. Tooling: Centers for the headstock and tailstock, assorted grinding dogs, composition hammer, assorted grinding wheels suitable for mounting to the spindle, files, magnetic base for indicators, and diamond dresser. Measuring Instruments:Required micrometers, combination set, dial test indicator, 6" rule, gage blocks, surface condition comparison gages. Reference: Machinery's Handbook. 29
KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Tapered Cylindrical Grinding Duty. Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Listening Isometric and Orthographic Sketching Measurements Mathematics X Basic Measurements X Arithmetic Optical Comparator Geometry of Compound Angles Geometry of Profiles of a Surface Manual Coordinate Measuring Machine Metalworking Theory Coordinate Axes, Cartesian & Polar X Cutting Theory Trigonometry for CNC Toolpaths CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving X Non-metal Properties & Cutting X Applying Decision CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Group Participation Personal Qualities Electrode Design and Selection Computers Typing Services of an Operating System 30
Machining Skills Level III Duty Area: 2. Job Execution Duty Title: 2.11 Grinding: Grind I.D. and O.D. Surfaces Duty: Set up and grind I.D. and O.D. surfaces on a universal grinding machine or OD/ID grinder. Performance Standard: Given a part rough finished on O.D.s and I.D.s, mount the part in an appropriate workholder and grind the diameters to the required finish. Grind the shoulders as necessary. Dress the wheel. Accuracy Level: +/-.015 on fractions, +/-.005 on decimals, +/-.0002 on ground diameters. Assessment Equipment and Material: Workstation: A standard workbench and I.D./O.D. grinder. Material: A part matching the material requirements of the blueprint, material: 1215 CRS. Tooling: Workholders, three- and four-jaw grinder's chucks, composition hammer, assorted grinding wheels suitable for mounting to the spindle, files, magnetic base for indicators, and diamond dresser. Measuring Instruments:Required micrometers, dial bore gages, dial test indicator, 6" rule, gage blocks, surface condition comparison gages. Reference: Machinery's Handbook. 31
KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Grinding I.D. and O.D. Surfaces Duty. Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Listening Isometric and Orthographic Sketching Measurements Mathematics XX Basic Measurements Arithmetic Geometry of Compound Angles Geometry of Profiles of a Surface Optical Comparator Manual Coordinate Measuring Machine Metalworking Theory Coordinate Axes, Cartesian & Polar X Cutting Theory Trigonometry for CNC Toolpaths CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving X Non-metal Properties & Cutting X Applying Decision CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Group Participation Personal Qualities Electrode Design and Selection Computers Typing Services of an Operating System 32
Machining Skills Level III Duty Area: 2. Job Execution Duty Title: 2.12 Grinding: Grind Tapers on a Universal Grinder Duty: Set up and grind tapers on a universal grinder. Performance Standard: Given a part rough finished on O.D.s and I.D.s, mount the part in an appropriate workholder and grind the tapered diameters to the required finish. Dress the wheel. Accuracy Level: +/-.015 on fractions, +/-.005 on decimals, +/-.0002 on ground diameters. Assessment Equipment and Material: Workstation: A standard workbench and universal grinder. Material: A part matching the material requirements of the blueprint, material: 1215 CRS. Tooling: Workholders, three- and four-jaw grinder's chucks, centers, drive dogs, indexers, composition hammer, assorted grinding wheels suitable for mounting to the spindle, files, magnetic base for indicators, live center, tailstock, and diamond dresser. Measuring Instruments:Required micrometers, dial bore gages, dial test indicator, 6" rule, gage blocks, surface condition comparison gages. Reference: Machinery's Handbook. 33
KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Grinding of Tapers on a Universal Grinder Duty. Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Listening Isometric and Orthographic Sketching Measurements Mathematics X Basic Measurements X Arithmetic Optical Comparator Geometry of Compound Angles Geometry of Profiles of a Surface Manual Coordinate Measuring Machine Metalworking Theory Coordinate Axes, Cartesian & Polar X Cutting Theory Trigonometry for CNC Toolpaths CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving X Non-metal Properties & Cutting X Applying Decision CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Group Participation Personal Qualities Electrode Design and Selection Computers Typing Services of an Operating System 34
Machining Skills Level III Duty Area: 2. Job Execution Duty Title: 2.13 Grinding: Contour Grinding Duty: Set up and grind curved and irregular surfaces by using linear incremental moves, tapers, radii, interpolation, and approximation with the aid of a visual comparator and a radius dresser. Performance Standard: Given a rough finished part, mount the part in an appropriate workholder and grind the profile to the required finish. Dress the wheel as necessary. Accuracy Level: +/-.015 on fractions, +/-.005 on decimals, +/-.0002 on ground surfaces, +/-5' on angles, 16 microinch finish. Assessment Equipment and Material: Workstation: A standard workbench and profile grinder. Material: A part matching the material requirements of the blueprint, material: A2 tool steel. Tooling: Workholders, grinder's vise, composition hammer, assorted grinding wheels suitable for mounting to the spindle, files, magnetic base for indicators, radius dresser, and diamond dresser. Measuring Instruments:Required micrometers, dial test indicator, 6" rule, gage blocks, visual comparator, surface condition comparison gages. Reference: Machinery's Handbook. 35
KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Contour Grinding Duty. Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Listening Isometric and Orthographic Sketching Measurements Mathematics X Basic Measurements X Arithmetic X Optical Comparator X Geometry of Compound Angles Manual Coordinate Measuring Machine X Geometry of Profiles of a Surface Metalworking Theory Coordinate Axes, Cartesian & Polar X Cutting Theory Trigonometry for CNC Toolpaths CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving Non-metal Properties & Cutting X Applying Decision CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Group Participation Personal Qualities Electrode Design and Selection Computers Typing Services of an Operating System 36
Machining Skills Level III Duty Area: 2. Job Execution Duty Title: 2.14 EDM: Operate a 4 Axis Wire EDM Duty: Operate a 4 axis wire electric discharge machine. Performance Standard: Given a print, process plan, an appropriate selection of wire electrodes, workholding devices, EDM fluids, and 4 axis wire EDM machine, perform the EDM operation called out on the process plan. Accuracy Level: Match the requirements of the blueprint. Assessment Equipment and Material: Workstation: A 4 axis wire EDM and a workbench. Material: A part matching the material requirements of the blueprint, material: 1018 HRS Tooling: An appropriate workholding device, screws, studs, nuts, washers, and clamps sufficient to secure the part to the table. Assorted parallels, files, magnetic base for indicators, and assorted hand tools. Measuring Instruments:Required micrometers, combination set, dial indicator, 6" rule, a 6" vernier, dial, or electronic caliper, adjustable parallels, edge finder, appropriate tools for determining squareness, and surface finish comparison standards. Reference: Machinery's Handbook. 37
KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Operation of a 4 Axis Wire EDM Duty. Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Listening Isometric and Orthographic Sketching Measurements Mathematics X Basic Measurements X Arithmetic X Optical Comparator X Geometry of Compound Angles X Manual Coordinate Measuring Machine X Geometry of Profiles of a Surface Metalworking Theory X Coordinate Axes, Cartesian & Polar X Cutting Theory X Trigonometry for CNC Toolpaths CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving X Non-metal Properties & Cutting X Applying Decision X CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities X Electrode Design and Selection Group Participation Personal Qualities Computers Typing Services of an Operating System 38
Machining Skills Level III Duty Area: 2. Job Execution Duty Title: 2.15 CNC: Advanced Manual RS-274-D Programming Duty: Using a computer and editor write sophisticated RS-274-D programs. Sophisticated programs will contain various combinations of change of plane, canned cycles, will employ multiple tools, cutter offsets, linear, circular and helical interpolation as well as requiring the matching of surfaces along lines and points of tangency in 3 axes. Store the results on computer media. Performance Standard: Given a blueprint and a process plan, write a program to drive a collection of tooling through the toolpaths needed to produce the part shown on the blueprint. The program will require change of tools, change of planes, use of "canned cycles", and tool offsets. Use a computer to write and store the program. Accuracy Level: Match the tolerance of the blueprint. Assessment Equipment and Material: Workstation: A personal computer, a software editor, and a printer. Material: A diskette and paper. Tooling: N/A. Measuring Instruments: N/A. Reference: Machinery's Handbook, EIA Standard RS-274-D, the manual for the machine tool the program is being written for. 39
KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the CNC Advanced Manual RS-274-D Programming Duty. Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views X Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Listening Isometric and Orthographic Sketching Measurements Mathematics X Basic Measurements X Arithmetic Optical Comparator X Geometry of Compound Angles Manual Coordinate Measuring Machine X Geometry of Profiles of a Surface Metalworking Theory X Coordinate Axes, Cartesian & Polar X Cutting Theory X Trigonometry for CNC Toolpaths X CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving X Non-metal Properties & Cutting X Applying Decision X CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Group Participation X Computers Personal Qualities X Typing X Electrode Design and Selection Services of an Operating System 40
Machining Skills Level III Duty Area: 2. Job Execution Duty Title: 2.16 CNC: Use Manufacturing Modeling Software to Create RS-274-D Programs Duty: Create RS-274-D programs using a manufacturing modeling software package. Performance Standard: Given a blueprint, use a graphics-based software package to develop a program to drive a collection of tooling through the toolpaths needed to produce the part shown on the blueprint. The program will require change of tools, change of planes, use of "canned cycles", and tool offsets. Accuracy Level: N/A. Assessment Equipment and Material: Workstation: A personal computer, a graphics-based tool path modeler/editor, a software editor, and a printer. Material: A diskette and paper. Tooling: N/A. Measuring Instruments: N/A. Reference: Machinery's Handbook, EIA Standard RS-274-D, the manual for the machine tool the program is being written for. 41
KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Use of Manufacturing Modeling Software to Create RS-274-D Programs Duty. Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views X Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Listening Isometric and Orthographic Sketching Measurements Mathematics X Basic Measurements X Arithmetic Optical Comparator X Geometry of Compound Angles Manual Coordinate Measuring Machine X Geometry of Profiles of a Surface Metalworking Theory X Coordinate Axes, Cartesian & Polar X Cutting Theory X Trigonometry for CNC Toolpaths X CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving X Non-metal Properties & Cutting X Applying Decision X CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Group Participation X Computers Personal Qualities X Typing X Electrode Design and Selection Services of an Operating System 42