Forming strip spring components using power rolling machines

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This standard identifies the competences you need to form materials used in the manufacture of strip springs, using power-operated pinch or pyramid rolls, in accordance with approved procedures. You will be required to operate the power rolling machine, according to the operations to be performed and the thickness and size of the material to be rolled. Preparing the rolls will involve setting and adjusting the gap between feed and forming rolls to suit material thickness, positioning side roller(s) and adjusting to suit the required radius, checking and setting parallelism of rollers, and applying suitable pressure to rollers throughout the forming operation.

You will be expected to carry out the rolling operation in a manner which ensures that the material is formed to the required profile, without flats or deformities. You will also need to ensure that all the required safety devices are operating correctly, and that the machine guards are in place and correctly adjusted. Items to be rolled will include mild steel, carbon steel, stainless steel, and alloys, and will involve operations such as flattening or straightening, producing curved profiles, rolling clock/power springs and constant force springs

Your responsibilities will require you to comply with organisational policy and procedures for the spring making activities undertaken, and to report any problems with the equipment, materials, or rolling activities that you cannot resolve, or that are outside your 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 the required power rolling procedures for strip springs. You will understand the rolling processes, the equipment and its application, and will know about the materials and rolling techniques in adequate depth to provide a sound basis for carrying out the activities, correcting faults and for producing the spring components to the required specification.

You will understand the safety precautions required when working with power rolls, and the safeguards necessary for undertaking the activities safely and correctly. You will be required to demonstrate safe working practices throughout, and will understand your responsibility for taking the necessary safeguards to protect yourself and others in the workplace.

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1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. confirm that the equipment is set up correctly and is ready for use
3. manipulate the machine controls safely and correctly in line with operational procedures
4. produce components to the required specification
5. carry out quality sampling checks at suitable intervals
6. deal promptly and effectively with problems within your control and report those that cannot be solved
7. shut down the equipment to a safe condition on conclusion of the machining activities

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1. how to work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. the importance of wearing the appropriate protective clothing (PPE) and equipment and of keeping the work area clean and tidy
3. the handling precautions and correct methods of moving or lifting sheet or plate materials, and the equipment to be used for this
4. the hazards associated with setting and using power rolling machines for spring work and how to minimise them and reduce any risks
5. checks to be carried out to ensure that the power rolls are safe and are in a fit condition to use
6. the safety mechanisms on the machine, and the procedure for checking that they function correctly
7. how to start and stop the machine in normal and emergency situations
8. the importance of ensuring that the machine is isolated from the power supply before setting up the various operating mechanisms
9. how to obtain the necessary drawings, specifications and job instructions
10. how to extract information from engineering drawings and related specifications (to include symbols and conventions to appropriate standards) in relation to work undertaken
11. how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing
12. terminology used in rolling machines and rolling operations in relation to the activities undertaken and types of spring produced
13. marking out conventions used in spring making, and how to recognise the centre lines, bending, forming and cutting lines
14. the basic principle of operation of the power rolling machine used, and the type of work it can perform
15. how to set up the machine to produce the required form (such as curved forms, circles and straightening materials)
16. techniques of rolling (including pre-setting plate edges, adjusting pressure throughout the rolling operations, checking the component for parallelism or form throughout the operations)
17. how to release the rolls and remove the workpiece when rolling cylindrical and conical sections
18. ways of limiting distortion, marks, creases and flats in curved sections
19. how the materials need to be prepared prior to rolling, and the effects of raw material scale or burrs on the finished article
20. material characteristics with regard to forming by using rolling machines
21. the care and maintenance procedures to be observed to ensure that the machines are in a serviceable condition
22. the organisational quality control procedures, and how to recognise rolling defects
23. the inspection checks to be carried out, and the tools and equipment that are used for this
24. the accuracy that can be achieved by rolling, and limitations of the rolling processes
25. the importance of completing all relevant documentation on conclusion of the spring making activities
26. the extent of your own authority and to whom you should report if you have problems that you cannot resolve

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1. Carry out all of the following in preparation for the power rolling spring making activities:
   1. obtain and interpret correctly the documentation for the type of spring being made
   2. 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
   3. check that the machine and rolls are in a safe and usable condition (suitable diameter, free from damage)
   4. set the rolls for the thickness of material being used, and the operations to be performed
   5. ensure that equipment is in place for supporting the material at the start of the rolling operations
   6. carry out the setting-up activities, following good practice/approved procedures
   7. ensure that correctly adjusted machine guards/safety devices are in place and operate correctly
   8. leave the machine and work area in a safe and clean condition on completion of the setting-up activities
2. Carry out rolling operations on two types of material from the following:
   1. mild steel
   2. alloy steel
   3. nickel based alloys
   4. carbon steel
   5. copper based alloy
   6. titanium and other special material
   7. stainless steel
   8. other specific material
3. Use one of the following types of power rolling machine:
   1. small rolls (hand adjusted)
   2. large rolls (console adjusted)
   3. variable rolls
4. Perform rolling operations that produce two of the following shapes/spring components:
   1. curved sections
   2. flattening or straightening material
   3. clock/power springs
   4. constant force springs
   5. spring rings
5. Produce rolled strip spring components which meet all of the following quality and accuracy standards:
   1. dimensional accuracy is within the tolerances specified on the drawing/specification
   2. the rolled material conforms to best practice and/or specification, without deformation or cracking
   3. the spring component conforms to the required shape/geometry

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3

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31 Mar 2028

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Current

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Original

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Enginuity

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SEMMME3137

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Engineering, Engineering and Manufacturing Technologies, Engineering Technicians

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3113

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mechanical engineering; spring making; forming; strip spring; power rolling; machines; curved sections; clock spring; power spring; spring rings; constant force springs; flattening; straightening; small rolls; hand adjusted; large rolls; console adjusted

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