Trimming composite mouldings using hand tools
Overview
This standard identifies the competences you need to trim composite mouldings using hand tools, in accordance with approved procedures. You will be required to follow the appropriate instructions, drawings, specifications and documentation to trim various composite mouldings, using the correct trimming techniques.
You will be expected to select and use the correct tools and equipment for the trimming activity. You will trim a range of composite mouldings, incorporating a variety of features, by using cutting, sanding, drilling and polishing techniques and processes. Mouldings to be trimmed will include a range of resin and fibre materials.
Your responsibilities will require you to comply with organisational policy and procedures for the trimming activities undertaken, and to report any problems with the trimming activities, equipment or materials that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work to instructions, 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 be sufficient to provide a good understanding of your work, and will provide an informed approach to applying composite moulding trimming techniques and procedures. You will have an understanding of the trimming techniques used, and their application, in adequate depth to provide a sound basis for carrying out the activities, recognising faults and ensuring the trimmed mouldings are to the required specification.
You will understand the safety precautions required when carrying out the trimming activities and when using the 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.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow relevant specifications for the moulding to be trimmed
- obtain the appropriate tools and equipment for the shaping operations and check they are in a safe and usable condition
- carry out any required preparation activities prior to undertaking the trimming operation
- trim the moulding using appropriate methods and techniques
- check that all the required shaping operations have been completed to the required specification
- complete relevant production documentation
- 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:
- health and safety precautions to be taken and procedures used when working with composite materials, consumables, tools and equipment in the specific work area
- the hazards associated with trimming composite materials, consumables, tools and equipment, and how to minimise these and reduce any risks in the work area
- protective equipment (PPE) that is needed for personal protection and, where required, the protection of others
- the application of COSHH regulations in relation to the storage, use and disposal of composite materials and consumables
- the specific environmental conditions the must be observed when trimming composite mouldings (such as temperature, humidity, fume/dust extraction systems and equipment)
- the importance of setting up and using dust control measures including segregated work areas, dust extraction, working practices and use of personal protective equipment (PPE)
- how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS, ISO or BSEN standards) in relation to work undertaken
- how to interpret drawings, imperial and metric systems of measurement, work piece reference points and system of tolerance
- how to prepare for the trimming activities, and how to mark out the mouldings for the material that needs to be removed
- quality procedures used in the workplace to ensure production control (such as in relation to currency, issue, meeting specification) and the completion of such documents
- conventions and terminology used for trimming activities (such as scribe lines, sanding grades, types of cutting tools, speeds)
- the different types of manual and power tools used in composite trimming operations
- how the type of material being trimmed can affect the selection of cutting media, tools and speeds
- the different types of cutting tools and abrasives used in trimming composite materials, and their application
- the visual identification of cured and non-cured composite materials
- the identification of defects in composite mouldings
- the methods used in the trimming of composite mouldings
- the sequence to be followed when preparing for trimming activities
- the care and safe handling of composite mouldings throughout the trimming cycle
- the extent of your own authority and to whom you should report if you have problems that you cannot resolve
Scope/range
Scope Performance
1. Carry out all of the following during the trimming activities:
1.1 obtain and use the appropriate documentation (such as job instructions, drawings, quality control documentation, material data sheets)
1.2 adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
1.3 obtain the correct tools and equipment for the activity and ensure they are safe to use
1.4 follow safe and appropriate trimming techniques and working practices at all times
1.5 segregate and dispose of waste materials using the correct procedure
1.6 return all tools and equipment to the correct location on completion of the trimming activities
1.7 leave the work area in a safe and suitable condition on completion of the activities
2. Carry out all of the following when preparing for the trimming activity:
2.1 check the moulding is correct and complete
2.2 check for any defects in the moulding
2.3 identify and protect the moulding in the work area
3. Mark out the mouldings using two of the following methods:
3.1 scriber
3.2 moulded scribe lines
3.3 trimming templates
3.4 height gauge
3.5 centre punch
3.6 scribing jigs
3.7 other specific method
4. Cut mouldings using two the following methods:
4.1 cutting wheels/discs
4.2 routers
4.3 saws
4.4 trim jigs
5. Sand mouldings using two of the following methods:
5.1 rubbing blocks
5.2 pencil grinders
5.3 belt sanders
5.4 diamond files
5.5 disc sanders
5.6 orbital sanders
6. Use a hand drill or pedestal drill to drill mouldings using one of the following methods:
6.1 drill jigs
6.2 counterbores
6.3 drill bits
6.4 hole saws
6.5 countersinks
7. Polish mouldings using two of the following methods if final finish is required:
7.1 wet sanding
7.2 polishing compound
7.3 orbital sander
7.4 cutting compound
7.5 rubbing block
7.6 polisher
8. Trim mouldings using techniques for one of the following resin types:
8.1. bio resin
8.2. thermoplastic
8.3. polyester
8.4. vinyl ester
8.5. epoxy
8.6. phenolic
8.7. bismaleimide
8.8. cyanate ester
8.9. other (to be specified)
9. Trim mouldings using techniques for one of the following fibre types:
9.1. natural fibre
9.2. thermo plastic
9.3. glass
9.4. aramid
9.5. carbon
9.6. hybrid
9.7. other specific types
10. Trim mouldings that require, or incorporate five of the following features:
10.1. straight edges
10.2. multiple holes
10.3. curved edges
10.4. multiple hole sizes
10.5. flat surfaces
10.6. countersinks
10.7. polished surfaces
10.8. counterbores
10.9. shaped surfaces
10.10. further lay-up stages
10.11. radius corners
10.12. inserts to be drilled
10.13. returns
10.14. inserts to be tapped
10.15. net edges
10.16. solid cores
10.17. joggle details
10.18. honeycomb cores
10.19. removal of join lines
10.20. edge filling/sealing
11. Trim a range of mouldings in compliance with one of the following standards:
11.1 BS, ISO or BSEN standards and procedures
11.2 customer standards and requirements
11.3 company standards and procedures
11.4 recognised compliance agency/body standards