Producing components using hand fitting techniques
Overview
This standard identifies the competences you need to produce detail components using hand fitting techniques, in accordance with approved procedures. You will be required to select the appropriate equipment to use, based on the operations to be carried out and the accuracy required. In producing the components, you will be expected to use appropriate tools and equipment to mark out the material for a range of features to be produced, and then to use hand tools, portable power tools, shaping and fitting techniques that are appropriate to the type of material and operations being performed. These activities will include such operations as hand sawing, band sawing, filing, drilling, chiselling, threading, scraping, lapping and off-hand grinding. The components produced will have features that include flat, square, parallel and angular faces, radii and curved profiles, drilled holes, internal and external threads, and sliding or mating parts.
Materials to be used will include ferrous, non-ferrous, non-metallic and composites, which may be in sheet form, bar sections or part-machined components.
Your responsibilities will require you to comply with organisational policy and procedures for the cutting and shaping activities undertaken, and to report any problems with the equipment, materials or 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 produce.
Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying hand fitting procedures. You will understand the hand fitting techniques used, and their application, and will know about the tools, materials and equipment used, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and producing the components to the required specification.
You will understand the safety precautions required when using hand and power tools. 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 component to be produced
- obtain the appropriate tools and equipment for the shaping operations and check they are in a safe and usable condition
- mark out, cut and shape the materials using appropriate methods and techniques
- produce components to required specification
- check that all the required shaping operations have been completed to the required specification
- complete the required 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:
- how to work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- the importance of wearing appropriate protective clothing (PPE) and equipment, and of keeping the work area safe and tidy
- the hazards associated with the carrying out hand fitting techniques and how to minimise them and reduce any risks
- the procedure for obtaining the required drawings, job instructions and other related specifications
- how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to appropriate standards) in relation to work undertaken
- how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing
- how to prepare the materials in readiness for the marking-out activities, in order to enhance clarity, accuracy and safety
- how to select and establish suitable datums
- the importance of ensuring that marking out is undertaken from the selected datums, and the possible effects of working from different datums
- methods of holding and supporting workpieces during the marking-out activities, and equipment that can be used
- use of marking out conventions when marking out the workpiece
- ways of laying out the marking-out shapes or patterns to maximise use of materials
- setting and adjusting tools, such as squares, protractors and verniers
- the importance of using tools only for the purpose intended; the care that is required when using the equipment and tools; the proper way of storing tools and equipment between operations
- the need for clear and dimensional accuracy in marking out to specification and drawing requirements
- the cutting and shaping methods to be used, and the sequence in which the operations will need to be carried out
- how to file flat, square and curved surfaces and achieve a smooth surface finish
- how to cut external threads using hand dies, and the method of fixing and adjusting the dies to give the correct thread fit
- how to determine the drill size for tapped holes, and the importance of using the taps in the correct sequence
- how to produce a sliding or mating fit using filing, scraping and lapping techniques
- how to select saw blades for different materials, and how to set the saw blades for different operations, such as cutting externally and internally
- the various types of file that are available, and the cut of files for different applications
- how to prepare the components for the filing operations
- the use of vice jaw plates to protect the workpiece from damage
- the types and application of portable power tools that can be used for the hand fitting operations
- the importance of ensuring file handles are secure and free from embedded foreign bodies or splits
- how to check that portable power tools and extension cables are free from damage and in a safe/tested usable condition
- the problems that can occur with the cutting and shaping operations, and how can these be overcome
- the extent of your own responsibility 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 activities during the hand fitting:
- obtain and use the appropriate documentation
- adhere to procedures or systems in place for risk assessment, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- follow safe practice/approved fitting procedures at all times
- check that all cables, extension leads or air supply hoses are in a serviceable condition
- check that all tools and measuring equipment are within current calibration/certification dates
- return all tools and equipment to the correct location on completion of the fitting activities
- leave the work area and machine in a safe and appropriate condition on completion of the activities
2. Mark out a range of material forms, to include five from the following:
- forgings
- round/cylindrical sections
- channel sections
- irregular shaped items
- machined items
- bar stock items
- angle irons
- assemblies
- castings
- flat or sheet materials
- joist sections
- other specific items
3. Use marking-out methods and techniques which include two of the following:
- direct marking using instruments
- use of templates
- tracing/transfer methods
4. Use a range of marking-out equipment, to include all of the following:
- rules/tapes
- scribers
- scribing blocks
- protractors
- dividers/trammels
- punches
- squares
- vernier instruments
5. Mark out workpieces which include five of the following features:
- datum/centre lines
- circles
- radial hole positions
- square/rectangular profiles
- radial profiles
- allowances for bending
- angles/angular profiles
- linear hole positions
- simple pattern development
6. Use a range of hand fitting methods to include seven from the following:
- filing
- off hand grinding
- scraping
- threads external
- lapping
- tapping
- drilling
- power sawing
- chiselling
- threads internal
- hand sawing
7. Produce components which combine several features and cover eight from the following:
- flat datum faces
- faces which are square to each other
- internal threads
- chamfers and radii
- faces which are parallel to each other
- external threads
- curved profiles
- drilled holes (through, to a depth)
- faces angled to each other
- reamed holes
- counterbores, countersinks, or spot face
- sliding or mating parts
8. Cut and shape two different types of material from the following:
- low carbon steel
- stainless steel
- brass/bronze
- composite
- high carbon steel
- aluminium
- plastic/synthetic
9. Produce components within all of the following standards, as applicable to the process:
- surface finish 63µin or 1.6 µm
- reamed and bored holes within H8
- screw threads to BS Medium fit
- flatness and squareness 0.001″ per inch or 0.025mm per 25mm
- dimensional tolerance as specified in relevant standard