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. 5245.0 5245.01 Operate emergency safety 5245.02 Practise industrial hygiene. 5245.03 in the workplace. 5245.04 Conduct preoperational check of 5245.05 Report injuries. 5245.06 Follow procedures for applying first aid. 5245.07 Lock out mechanical 5245.08 Handle designated substances. 5245.09 Operate lifting 5245.10 Follow hot-runner safe testing procedures. 5245.11 5245.12 5245.13 5245.14 5245.15 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. 5246.0 5246.01 machines. 5246.02 check machine controls and systems. 5246.03 select tooling. 5246.04 prepare cutting 5246.05 measuring instruments and checking devices. 5246.06 Select machine speeds and feeds. 5246.07 Lay out features of engineering drawings. 5246.08 select workholding devices. 5246.09 Pick up datum/starting. 5246.10 lifting and rigging 5246.11 Communicate with co-workers. 5246.12 5246.13 5246.14 5246.15 5246.16
WORK-IN- PROCESS DIMENSIONAL OR SURFACE VERIFICATION Check straight cuts. Check shapes. Check threads. Check holes. Check tapers. 5247.0 5247.01 Check hardness. 5247.02 Deburr 5247.03 5247.04 Check surfaces. 5247.05 5247.06 5247.07 5247.08 5247.09 5247.10 5247.11 BENCHWORK Hand-file. Hand-saw. Hand-drill holes. Hand-tap threaded holes. Hand-ream. 5248.0 5248.01 Chase threads. 5248.02 Hand-grind. 5248.03. 5248.04 5248.05 5248.06 5248.07 5248.08
SAWING Check fused/welded blade. Lay out features of engineering drawings. workpiece in saw. feeds of saw. Install and test-run blade. 5249.0 Check first cut-off. 5249.01 5249.02 Cut shapes using a vertical bandsaw. 5249.03 Cut squared and angled surfaces using a power cut-off saw. 5249.04 5249.05 Deburr 5249.06 5249.07 5249.08 5249.09 Move workpiece.. 5249.10 5249.11 5249.12 5249.13 5249.14 DRILLING USING DRILL PRESS/ MACHINE Select drill tooling. prepare cutting tools for drills. workpiece in drill. Set up tooling in drills. feeds of drill. 5250.0 5250.01 Centre-drill a layout punch mark. 5250.02 Drill a hole. 5250.03 Chamfer a hole. 5250.04 Ream a hole. 5250.05 Machine-thread a hole. 5250.06 Spot-face a hole. 5250.07 Counter-bore a hole. 5250.08 Counter-sink a hole. 5250.09 5250.10 Deburr 5250.11 5250.12 Move 5250.13. 5250.14 5250.15 5250.16 5250.17 5250.18 5250.19
MACHINE GRINDING Select grinding wheel. Check condition of grinding wheel. Install grinding wheel. workpiece in grinder. Surface grind 5251.0 Hone holes 5251.01 5251.02 Lap workpiece 5251.03 Grind inside and outside diameters. (ID/OD) 5251.04 Grind tools and cutters. 5251.04 Check ground surfaces. 5251.05 5251.06 Move 5251.07 5251.08 5251.10 5251.11 5251.12 5251.13 5251.14 LATHE WORK Select lathe cutting prepare lathe workpiece in lathe. Set up lathe feeds of lathe. 5252.0 5252.01 Take a sizing (preliminary) cut. 5252.02 Establish a reference or starting point.(datum) 5252.03 Face a surface. 5252.04 Turn an external diameter. 5252.05 Drill a hole. 5252.06 Bore an internal diameter. 5252.07 Ream a hole. 5252.08 Tap a hole. 5252.09 Turn an internal or external thread. 5252.10 Produce a taper. 5252.11 Knurl cylindrical surface patterns. 5252.12 Groove and part-off 5252.13 5252.14 Deburr 5252.15 5252.16. 5252.17 Move workpiece 5252.18 5252.19 5252.20 5252.21 5252.22 5252.23
MILLING Select milling prepare milling Set-up and maintain milling adjustable support Set-up milling feeds of mill. 5253.0 5253.01 Perform fly-cutting. Face-mill. 5253.02 5253.03 Machine steps, cut-outs, angles, and open slots. 5253.04 Machine a pocket or slots. 5253.05 Machine a hole 5253.06 Bore holes. 5253.07 5253.08 Deburr 5253.09 5253.10 Move 5253.11 5253.12 5253.13 5253.14 5253.15 5253.16 5253.17 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. 5254.0 5254.01 5254.02 5254.03 5254.05 5254.05 Verify tool sequence, tool path, & collision avoidance program. Monitor NC/CNC machining process. Make adjustments to tooling and offsets inspection 5254.06 5254.07 5254.08 5254.09 5254.10 Move 5254.11 5254.12 5254.13
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. 5255.0 5255.01 Input and verify part program to the EDM machine controls. 5255.02 Cut workpiece by EDM machining. 5255.03 5255.04 5255.05 Move workpiece 5255.06 5255.07 5255.08 5255.09 5255.10 5255.11 5255.12 DEVISE AND DETAIL A PLAN FOR THE MOULD- BUILDING PROCESS 5256.0 Verify features of the mould 5256.01 Build tooling aids for mould-building process. Develop and organize a mouldbuild plan. 5256.02 Lay out template(s). Perform mouldbuilding related calculations. Produce templates. 5256.03 Assemble and verify tooling stock materials. 5256.04 Produce a detailed sketch of mould 5256.05 5256.06 5256.07 5256.08
BUILD/ FABRICATE MOULD COMPONENTS Rough-out mould components Stabilize workpiece material. Produce cores. Produce lifters, inserts, and slides. Produce cavities. 5257.0 5257.01 Produce detailed parts. 5257.02 5257.03. 5257.04 5257.05 Move 5257.06 5257.07 5257.08 5257.09 5257.10 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. 5258.0 Final-inspect mould. 5258.01 5258.02 Install ejector system 5258.03 Install runner system 5258.04 Check assembled mould. 5258.05 Move 5258.06 5258.07 5258.08 5258.09 5258.10 5258.11 FINISH/POLISH THE MOULDING SURFACE hand-finishing Clean and deburr mould surface. Detail the Remove tool and cutter marks. Verify contours of the 5259.0 5259.01 Final-finish the mould surface. 5259.02. 5259.03 Move workpiece 5259.04 5259.05 5259.06 5259.07 5259.08