Carrying out CNC fabrication machine tool programming
Overview
This standard identifies the competences you need to produce, load and prove machine tool programs on computer numerically controlled (CNC) fabrication machine tools, in accordance with approved procedures. The CNC machines covered by this standard include shearing, punching, bending and forming, plasma, laser, water jet and gas cutting machines. You will be required to produce the component program, using manual data input or by use of a remote computer, saving the prepared program on to storage media, or downloading it directly into the machine controller from the computer. You will need to check the program using single block run and program edit facilities. You will also be required to adjust the machine tool equipment and program, following the proving/editing activities, to achieve the component specification. You must ensure that any edited programs are saved safely and correctly.
Your responsibilities will require you to comply with organisational policy and procedures for producing, loading and proving the programs and to report any problems with these activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out. **
Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to applying the machine tool programming procedures used. You will understand the CNC fabrication machine tools used in the process and their application and will know about the programming, editing and proving process, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring that the machine controller is set up to produce the components to the required specification.
You will understand the safety precautions required when working on the machine and with its associated tools and equipment. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace.
Note: Setting workholding devices and tooling is the subject of other standards.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- use the correct control program and ensure it is correctly loaded into the machine controller
- follow the correct procedures for calling up the program and dealing with any error messages or faults
- confirm program integrity
- adjust the equipment and program operating parameters to optimise the outcomes to be achieved
- load and correctly set-up all associated equipment
- check that all safety mechanisms are in place and that the equipment is set correctly for the required operations
- deal promptly and effectively with problems within your control and report those that cannot be solved
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken when loading and proving CNC fabrication machine tool operating programs
- how to start and stop the machine, in normal and emergency situations
the importance of wearing the appropriate protective clothing and equipment (PPE) and of keeping the work area clean and tidy
the computing/coding language used in CNC programs with regard to machine axes, positional information, machine management and auxiliary functions
- the methods and procedures used to minimise the chances of infecting a computer with a virus
- the implications if the computer you are using does become infected with a virus and who to contact if it does occur
- how to use and extract information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS or ISO standards) in relation to work undertaken
- how to interpret first and third angle drawings, imperial and metric systems of measurement, and system of tolerancing
- how to interpret CNC drawings and the use of workpiece zero/reference points
- how to carry out currency/issue checks of the specifications you are working with
- the systems of measurement used on CNC drawing (including absolute and incremental)
- the use of repetitive programs and canned cycles to reduce program size and inputting time
- how to prepare part programs, using operational sequences and machining techniques which avoid unnecessary tool/cutter head movements or tool changes
- the function keys and operating system of the machine computer control system being operated
- how to set machine datums for each machine axis being used
- how to set the machine controller in the program and editing mode and how to enter or download the prepared program
- how to deal with error messages and faults on the program or equipment
- how to access the program edit facility, in order to enter tooling data (such as tool datums, positions, lengths, offsets and radius compensation)
- the use of tool-posts, magazines and carousels and how to identify the tools in relationship to the operating program
- how to conduct trial runs using single-block run, dry run and feed and speed over-ride controls
- factors that will affect the feeds and speeds that can be used and why they may need to be adjusted from the program setting (such as condition of material, workholding method, tooling used, tolerance and finish to be achieved)
- the items that you need to check before allowing the machine to operate in full program run mode
- how to save the completed programs in the appropriate format and the need to store program storage media safely and correctly, away from contaminants and sources of corruption
- typical problems that can occur with the programming, loading and editing activities and what to do if they occur
- the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve
Scope/range
Scope Performance
Apply all of the following checks and practices during the machine tool programming activities:
- obtain the correct component drawing and check it for currency and validity
- use the appropriate reference manuals and programming codes to suit the machine controller
- prepare the machine controller to accept the operating program
- input/load the prepared program into the controller, safely and correctly
- save programs safely and correctly, in the appropriate format
- store completed program media safely away from contaminants or electromagnetic sources
Prepare, load and prove programs for one of the following types of CNC machine tool:
- shearing machine
- punching machine
- forming machine
- bending machine
- plasma cutting
- laser cutting
- gas cutting
- water jet cutting
Produce CNC programs using one of the following methods:
- written
- entered directly into the machine controller
- using computer software
Develop part programs, which contain all of the following:
- all necessary positional information
- appropriate letter address codes
- preparatory commands and machine management/auxiliary functions
- repetitive programs (sub-routines, canned cycles, labels)
- absolute or incremental systems of measurement
- tool/cutter change/stop positions
- tool information (lengths, off-sets, radius compensation)
Prove the part program, using six of the following:
- single block run
- graphic displays
- full dry run
- search facilities
- program save/store facilities
- edit facilities
- program override controls (speed, feed, tool data)
- data input facilities
Confirm that the machine and program operates safely and correctly, by checking all of the following:
- all operations are carried out to the program co-ordinates
- tool change/park positions are safe and clear the workpiece and machine equipment
- the correct tools are selected at the appropriate points in the program (where applicable)
- tool/cutter head paths are executed safely and correctly
- auxiliary functions operate at the correct point in the program (cutter start/stop, coolant flow)
- programs have been saved in the appropriate format
Scope Knowledge
Values
Behaviours
Behaviours:
You will be able to apply the appropriate behaviours required in the workplace to meet the job profile and overall company objectives, such as:
- strong work ethic
- positive attitude
- team player
- dependability
- responsibility
- honesty
- integrity
- motivation
- commitment