QETA/046 Advanced milling Credit Value 10 QCF Level 3 GLH 75 Unit purpose/aims Learner pack This unit enables you to acquire the skills and essential background knowledge relating to advanced milling techniques, tooling, workholding and the checking of milled components against specification. Summary of learning outcomes You will: 46.1 Understand milling operations, equipment and procedures 46.2 Understand the use and functions of rotary tables and dividing heads 46.3 Understand types and uses of cutting tools and boring heads used in milling operations 46.4 Understand quality requirements of checking milled components Assessment of the unit This unit is assessed by an internally marked short answer question paper that will cover the underpinning knowledge for outcomes 46.1 to 46.4 and also an internal practical assessment that cover learning outcomes 46.1 to 46.4 Page 1 of 10
Unit 46 Learner instructions Internal assessment 46.1, 46.2, 46.3 and 46.4 WHY are we doing this? To demonstrate that you can work safely in a milling (machining) environment To demonstrate that you can use a Milling Machine and ancillary equipment to machine a simple component To demonstrate your underpinning knowledge of the Milling Machine, work holding equipment, rotary table, dividing head, milling cutters, dimensional accuracy, surface finish and material specification WHAT do we need? Task sheets Copy of assessment sheets Mild steel bar Milling Machine (Vertical), rotary table, dividing head, ground parallel diameter setting bars, parallel strips, collet chuck Rule, Micrometer, Dial Test Indicator, Square, Scriber, Protractor/Combination Set Milling cutters: o Face Mill o End Mill o Slot Drill o Side and Face Cutter o Angle Cutter o Dovetail Cutter o Boring Tool o Drills HOW do we make a start? Observe health and safety procedures at all times. 1. Dividing Head Exercise (All milled flats to leave a witness of the stock diameter) Select suitable diameter bar approx. 30mm diameter mild steel bar Saw off to length (155mm) Face ends to 150mm and centre drill Mount dividing head, with a 3 jaw chuck and tailstock and set parallel Mount work in chuck and tighten tailstock centre into work Mount and secure suitable diameter end mill Calculate cutting speeds and feeds Calculate indexing requirements for DIRECT INDEXING for 3 and 4 flats Calculate indexing requirements for SIMPLE INDEXING for7, 8, 9 flats 10mm wide Calculate indexing requirements for ANGULAR INDEXING for7 holes spaced as per drawing and to 5mm diameter and 5mm deep Turn work round and grip on the three flats taking care to protect the finish Set one flat parallel to the machine table Calculate indexing requirements for SIMPLE INDEXING for 6 enclosed slots Mount and secure suitable diameter slot drill Set table stops to give the required length of enclosed slot Machine enclosed slots Calculate indexing requirements for SIMPLE INDEXING for 3 open ended slots and rotating the slot through 20 Machine slots Remove burrs Final inspection and report completion Page 2 of 10 Continued on next page
Unit 46 Learner instructions Internal assessment 46.1, 46.2, 46.3 and 46.4 2. Rotary Table Exercise (Geneva Wheel) Select suitable diameter bar approx. 100mm diameter mild steel bar Saw off to thickness 23mm Face both sides to 20mm, centre drill and drill suitable diameter hole to enable you to clamp onto the rotary table Mount and set rotary table Mount, secure and set work on rotary table with suitable thin packing underneath Calculate cutting speeds and feeds Select suitable end mill and mill 6 equally spaced open ended slots 30mm long Mount boring head and set to machine 6 concave grooves 20mm radius to leave 5mm width on either side of radius Remove burrs Final inspection and report completion Page 3 of 10
Page 4 of 10
Page 5 of 10
Unit.. Learner report Internal assessment(s):-. Learner name: Date: Assessment title: - Learner no: Page.. of Report: - Assessors Comments: Assessor Signature Date Page 6 of 10
2010 EMTA Awards Limited All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of EAL EMTA Awards Limited Requests should be made in writing and addressed to: Product Development, EAL EMTA Awards Limited, 3365 Century Way, Thorpe Park, Leeds LS15 8ZB. Page 10 of 10