QETI/018 Turning and milling machining techniques and technology Credit Value 7 QCF Level 2 GLH 50 Unit purpose/aims Learner pack This unit enables you to acquire the essential knowledge and practice to achieve turning and milling skills. Summary of learning outcomes You will: 18.1 Understand the equipment and procedures used in turning and milling operations 18.2 Understand how to use work holding equipment correctly 18.3 Understand the types and applications of cutting tools 18.4 Understand the quality/standards requirements associated with turning and milling operations Assessment requirements An internally assessed multiple choice/ short answer question paper that assess the knowledge requirements of learning outcomes 18.1-18.4. An internally assessed task that covers the practical requirements of learning outcomes 18.1 to 18.4 Page 1 of 12
Learner instructions Internal assessment 18.1, 18.2, 18.3 and 18.4 - Turning WHY are we doing this? To demonstrate that you can work safely in a turning (machining) environment. To demonstrate that you can use a Centre Lathe and ancilliary equipment to machine a simple component. To demonstrate your underpinning knowledge of the Centre Lathe, work holding equipment, cutting tools, dimensional accuracy, suface finish and material specification WHAT do we need? Learner instructions and drawings Learner report sheets Centre Lathe 3 and 4 Jaw Chucks Live Centre Dead/Revolving Centre Callipers Rule Micrometer Dial Test Indicator Mild steel bar (as detailed in drawing) Brass bar Cutting tools: o knife o turn and facing o parting o chamfering o knurling tool o centre drill o twist drills o stock o die o tap wrench o taps o hacksaw HOW do we make a start? Observe health and safety procedures at all times. 1. Step Turning A, B, C Select material Mild steel bar (as detailed in drawing) Saw off to length Remove burrs Calculate spindle speeds Mount bar in 4 Jaw Chuck Face end Centre drill Support with revolving centre Turn diameters A, B, C Remove from chuck 2. Step Turning D, E, F Remove 4 jaw chuck and replace with 3 jaw chuck Grip on diameter A (protect finish) Face end Centre drill Support with revolving centre Turn diameters D, E, F Remove all sharp edges Final inspection and report completion Page 2 of 12 Continued on next page
Learner instructions (cont) Internal assessment 18.1, 18.2, 18.3 and 18.4 - Turning 3. Short Answer/Multiple choice question sheet (covering all Learning outcomes 18.1, 18.2, 18.3 and 18.4). The question paper is attached to LO 18.4 Read the guidance sheet and ensure you fully understand it prior to attempting the question paper Page 3 of 12
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Learner report Internal assessment 18.1, 18.2, 18.3 and 18.4 - Turning Learner name: Date: Assessment title: Learner no: Page.. of Report: Assessors comments: Assessor signature Date Page 5 of 12
Learner instructions Internal assessment 18.1, 18.2, 18.3 and 18.4 - Milling 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, milling cutters, dimensional accuracy, surface finish and material specification WHAT do we need? Learner instructions and drawings Learner report sheets Mild steel bar (as detailed in drawing) Rule Micrometer Dial Test Indicator Square Scriber Protractor/Combination Set Milling Machine (Horizontal and Vertical) Milling cutters: o slab mill o face mill o end mill o slot drill o side and face cutter o angle cutter o slitting saw Machine vice Parallel strips Collet chuck HOW do we make a start? Observe health and safety procedures at all times. 1. Milling Exercise Select Mild steel bar (as detailed in drawing) Saw off to length Remove burrs Calculate cutting speeds and feeds Select suitable cutter Mount bar in machine vice Mill flat face (de-burr) (A) Turn machined face to fixed jaw of vice and mill flat face (de-burr) (B) Check machined faces are square to each other Machine 3 rd and 4 th faces down to size (checking squareness to each other and de-burr) (C,D) Turn work on its end and set up vertical using a square Machine end and check squareness with machined faces (de-burr) (E) Machine remaining face to size and squareness (de-burr) (F) Final inspection and report completion 2. Produce Vee Grooves Set vice square to back face of machine using a Dial Test Indicator Mark out vee grooves Calculate cutting speeds and feeds Position work in vice and machine first vee groove to size (de-burr) (A) Position work in vice and machine second vee groove to size (de-burr) (C) Position work in vice and machine saw cuts in the bottom of vee grooves (de-burr) Final inspection and report completion Continued on next page Page 6 of 12
Learner instructions Internal assessment 18.1, 18.2, 18.3 and 18.4 - Milling 3. Produce Slots and Shoulder Mark out slots Calculate cutting speeds and feeds Position work in vice and machine first open ended slot to size (de-burr) (face A) Position work in vice and machine second open ended slot to size (de-burr) (face C) Position work in vice and machine first shoulder (de-burr) (face F) Machine second shoulder (de-burr) (face F) Machine enclosed slots (de-burr) (faces B D) Final inspection and report completion 4. Short Answer/Multiple choice question sheet (covering all Learning outcomes 18.1, 18.2, 18.3 and 18.4) The question paper is attached to LO 18.4 Read the guidance sheet and ensure you fully understand it prior to attempting the question paper Page 7 of 12
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Learner report Internal assessment 18.1, 18.2, 18.3 and 18.4 - Milling Learner name: Date: Assessment title: Learner no: Page.. of Report: Assessors comments: Assessor signature Date Page 9 of 12
Short answer/multiple choice question sheet Internal assessment 18.1, 18.2, 18.3 and 18.4 Milling and Turning Learner name: Date: Learner no: Attempt no: Marks 24 1. Name the two main types of conventional milling machines? /2 a. b. 2. Vibration and chatter on a horizontal milling can be kept to a minimum by? /1 a. Reducing the feed b. Increasing the cutting speed c. Placing the over arm support as close as possible to the cutter d. Increasing the feed 3. Describe the difference between up-cut/conventional milling and down-cut/climb milling? max 4 marks 4. Horizontal milling cutters are held on a? /1 a. Collet chuck b. Arbor c. Tool post d. Jacobs chuck 5. Briefly state what the following cutters are used for? 5 marks a. Slab mill b. Face mill c. Side and face cutter d. End mill e. Slot drill 6. What is the main difference between a plain machine vice and a swivel machine vice? /1 a. Plain vice is difficult to angular position b. Plain vice can only be used parallel or at 90º to back face of machine c. Swivel vice can easily be set at any angle d. Swivel vice cannot be used parallel or at 90º to back face of machine 7. What is the purpose of locking slides when machining? /1 a. To stop you moving the slide handles b. To reduce vibration c. To help produce a better finish d. To slow down the feed rate 8. What are parallel strips used for? 1 mark Continued on next page Page 10 of 12
Short answer/multiple choice question sheet Internal assessment 18.1, 18.2, 18.3 and 18.4 Milling and Turning 9. The Apron of a centre lathe enables? /1 a. Tools to be stored safely b. The spindle speed to be changed? c. The feed to be engaged d. Tapered parts to be turned 10. Vibration and chatter can be kept to a minimum by? /1 a. Reducing the feed b. Increasing the cutting speed c. Cutting down the amount of tool deflection d. Increasing the feed 11. What is the primary function of a revolving centre /1 a. Supporting the work piece b. Lining up the headstock and tail stock c. Setting tools d. Improving the cutting characteristics 12. The 4 Jaw Chuck is generally used for holding? /1 a. Very large work b. Castings c. Work requiring high clamping pressure d. Various shapes of work 13. The effect of setting a lathe tool a small amount below the centre of the work is to? /1 a. Increase the rake angle b. Decrease the rake angle c. Cut with negative rake d. Leave the rake unaltered 14. Tungsten is added to high speed steel to? /1 a. Make the material more ductile b. Prevent the material cracking during hardening c. Increase its hardness at high temperature d. Make the material easier to forge 15. Standardisation /1 a. Gives the consumer a larger range of products to choose from b. Gives the consumer a smaller range of products to choose from c. Stops wasteful diversity d. Increases inspection 16. Tolerance is referred to as? /1 a. The maximum permissible size b. The minimum permissible size c. The mean size d. The difference between the maximum and minimum sizes Learners and/or assessors comments Assessor signature Pass mark 14/24 Actual mark /24 Date of re-assessment (if applicable) Page 11 of 12
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