Cleaning metallic castings manually
URN: SEMMPF221
Business Sectors (Suites): Materials Processing and Finishing Suite 2
Developed by: Enginuity
Approved on:
30 Mar 2020
Overview
| This standard identifies the competences you need to manually clean castings produced from sand or ceramic moulds, investment shells or dies. You will be required to select the appropriate equipment to use, based on the type, size, number and alloy of the castings to be cleaned. They will have been produced as one-offs or in batches and will generally be non-ferrous. The castings will have been knocked out and de-cored and you will remove any adhering sand from both external and internal surfaces. Joint line and core print flash will be removed, along with any runners, risers or feeders that can be removed by manual methods. You will be expected to use workholding devices attached to benches and to manipulate the castings to complete the operations. There could be occasions when larger castings are sited on the floor, and you will be expected to manoeuvre these to complete the cleaning. Metal waste removed from the castings will be segregated, marked up and removed to designated areas. Your responsibilities will require you to comply with organisational policy and procedures for the manual cleaning of the castings. You will report any problems with the cleaning activities or with the tools in use that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work to verbal or written instructions and to take responsibility for the safe and correct cleaning of the rough castings. Your underpinning knowledge will be sufficient to provide a sound basis for your work and will enable you to adopt an informed approach to the cleaning of various types and size of castings. You will understand the different tools used, and how to use them for cleaning the various types of casting. You will be familiar with the lifting and moving equipment used to handle the different types and size of castings. You will understand the safety precautions required when carrying out the cleaning activities and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout. You will also understand your responsibilities for safety and the importance of taking the necessary safeguards to protect yourself and others in the workplace. |
Performance criteria
You must be able to:
| 1. work safely at all times, complying with health and safety, environmental and other relevant regulations, directives and guidelines 2. follow relevant work instructions and specifications to clean metal castings manually 3. obtain the required materials and check they meet quantity and quality specifications 4. prepare for, and carry out cleaning operations 5. check operations are complete and cleaned castings meet specifications 6. deal promptly and effectively with problems within your control and report those that cannot be solved 7. ensure that work records are completed, stored securely and available to others, as per organisational requirements 8. leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements |
Knowledge and Understanding
You need to know and understand:
| 1. the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials) 2. the health and safety requirements of the work area and the activities, and the responsibility these requirements place on you 3. the hazards associated with the activities, and how to minimise them and reduce risks 4. the personal protective equipment and clothing (PPE) to be worn during the activities 5. why different methods of cleaning castings are used for different moulding materials 6. the difference between sand moulds and ceramic moulds/shells 7. the various hand tools that are used to carry out the cleaning activities 8. the reasons why different tools are used to clean ferrous and non-ferrous castings 9. the various workholding methods and devices used to hold the castings during the cleaning activities 10. the checks to be made on the tools and equipment to ensure that they are in a safe and usable condition 11. the casting defects which can be directly related to using incorrect methods to remove runners/risers/feeders from castings during cleaning 12. the reasons why runners/risers/feeders need to be identified 13. why some materials can be returned for recycling, why others must be disposed of and why some need specialist methods of disposal 14. the importance of keeping the equipment clean and free from damage, good housekeeping of tools and equipment and maintaining a clean working area 15. the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve when cleaning the castings 16. how to access, use and maintain information to comply with organisational requirements and legislation |
Scope/range
Scope Performance
| 1. Prepare to clean castings manually, carrying out all of the following activities: 1. obtain all necessary documents and job instructions for the cleaning operations being performed 2. adhere to health and safety regulations, systems and procedures to realise a safe system of work 3. check that all the machine controls are operating safely and correctly (mechanical parts, circulating pumps, hydro supply, nozzles are clean and undamaged) 4. check that necessary services are connected and operational 5. check that any lifting and handling equipment required is available and in good order 6. ensure that dust extraction and air filtering equipment is functioning correctly 7. ensure that any tracks or carousels are operational 2. Clean castings which have been produced from one of the following materials: 1. ferrous alloys 2. non-ferrous alloys 3. Manually clean the castings using hand tools, to include all of the following: 1. using workholding devices (vice, clamps, jigs and fixtures) 2. removing joint line flash and runners/risers/feeders 3. segregation and identification of runners/risers/feeders as appropriate 4. disposal of removed materials as appropriate (returned for reclamation, placed in waste skips for normal disposal or in special skips for specialist disposal) 4. Use three of the following tools to remove adhering sand, joint line flash and runners/risers/feeders: 1. wire brushes 2. files 3. abrasive papers 4. scrapers 5. abrasive stones 6. hammers 7. hacksaws 5. Complete the visual inspection and segregate castings into all of the appropriate categories: 1. acceptable castings 2. castings requiring further cleaning operations 3. scrap castings 4. castings requiring further inspection by supervision 6. Complete all of the following operations at shut-down: 1. close down any machinery or equipment used during cleaning operations (such as extraction units, power supplies, air supplies, filtering equipment) 2. check that all systems are failsafe 3. complete the operational log |
Scope Knowledge
Values
Behaviours
Skills
Glossary
Links To Other NOS
External Links
Version Number
2
Indicative Review Date
31 Mar 2023
Validity
Current
Status
Original
Originating Organisation
Semta
Original URN
MPF2.21
Relevant Occupations
Engineering and Manufacturing Technologies, Manufacturing Technologies, Process Operatives, Process, Plant and Machine Operatives
SOC Code
8115
Keywords
Engineering; manufacturing; processing; cleaning; metallic; casting; manual; hand tools; abrasives