Fettling metallic castings
URN: SEMMPF223
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 use hand, power tools and/or automated equipment to fettle castings produced from sand moulds, ceramic moulds or investment shells. This will involve removing flash and other irregularities and polishing the surfaces of the castings. The standard includes ferrous and/or non-ferrous castings. You will be required to select the appropriate equipment to use, based on the type, size, number and alloy of the castings to be fettled. The castings will have been produced as one-offs, in batches or by the continuous casting process. You will be expected to carry out checks on the tools and equipment, to ensure that they are safe to use and to ensure that the abrasive wheels and/ or discs to be used during the fettling operation are available and suitable for the material and intended purpose. The castings could be circular, square or irregular in shape and may have projections and internal cavities. The profiles could be curved or tapered. You will receive them singly, in batches or in skips. You will remove the runners and risers/feeders, using manual or mechanical means. Other surplus metal present, on both external and internal surfaces (joint line and core print flash) must also be removed. You will operate fixed and portable machines to remove other surface protrusions and where appropriate, you will polish the castings in accordance with procedures. You will use workholding devices, benches and lifting equipment to manipulate the castings during the fettling operation. There could be occasions when larger castings are sited on the floor and you will be expected to manoeuvre these to complete the fettling. Fettled castings will be placed in skips, on pallets, in racks or in other specified containers or jigs. Metal waste removed from the castings will need to be segregated, marked up and removed to designated areas. Your responsibilities will require you to comply with organisational policy and procedures for the fettling of the castings. You will report any problems with the fettling activities, tools, machines and abrasive substances 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 fettling 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 fettling of various types and sizes of casting. You will understand the different tools, machines and abrasives used during the fettling operations and their applications. You will be familiar with the lifting and moving equipment which is used to handle the different types and sizes of casting. You will understand the safety precautions required when carrying out the fettling 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 legislation, regulations, directives and other relevant guidelines 2. follow relevant work instructions and specifications to fettle metallic castings 3. obtain the required materials and check they meet quantity and quality specifications 4. prepare for, and carry out fettling operations 5. check operations are complete and fettled 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. how to obtain the job instructions and how to interpret their information 6. how to set up and use dust extraction equipment and the importance of ensuring that the equipment is operating correctly 7. the emergency procedures to be followed in the event of a malfunction of any of the equipment that you use 8. why different methods of fettling castings are used for different metal alloys 9. the various hand and power tools that are used to carry out the fettling 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 difference between sand moulds and ceramic moulds/shells 12. the effect on casting quality of incorrectly fettling of castings (under or over-dressing) 13. the reasons why different types of equipment are used to fettle ferrous and non-ferrous castings 14. the reasons why different grades of abrasives are used to clean ferrous and non-ferrous castings 15. the defects which can be caused by using incorrect methods to remove runners/risers/feeders from castings during fettling (undercutting, proud finish) 16. the reasons why runners/risers/feeders need to be identified 17. the importance of keeping the equipment clean and free from damage, good housekeeping of tools and equipment and maintaining a clean working area 18. the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve 19. how to access, use and maintain information to comply with organisational requirements and legislation |
Scope/range
Scope Performance
| 1. Prepare for fettling, by carrying out all of the following, activities: 1. obtain all necessary documents and job instructions for the fettling operations being performed 2. adhere to health and safety regulations, systems and procedures to realise a safe system of work 3. check that all necessary services are connected and operational 4. check that lifting and handling equipment required is available and in good order 5. check that the tools and equipment are available and in a safe and usable condition (extension leads, hoses, pneumatic equipment, hand tools) 6. ensure that dust extraction and air filtering equipment is functioning correctly 7. ensure that any tracks or carousels are operational 2. Fettle castings which have been produced from one of the following materials: 1. ferrous alloys 2. non-ferrous alloys 3. Remove joint line flash and runners/risers/feeders of castings, using three of the following: 1. manual removal using hand tools 2. slitting saws 3. disc/angle grinders 4. thermal cutters (manually or mechanically operated) 5. linishers 6. pedestal grinders 7. pneumatic chipping hammers 8. laser cutters 9. band saws 10. automated equipment 11. other types of equipment (specify) 4. Dress castings with all of the following shapes: 1. circular 2. irregular 3. curved or tapered profiles 4. square 5. projections or internal cavities 5. Monitor the equipment performance during the fettling operation, checking all of the following: 1. supply pressure of services 2. security of the abrasive wheels 3. extraction equipment functioning 4. escape of air 5. filtration systems functioning 6. tool tip wear 7. abrasive condition 6. Complete the visual inspection and segregate castings into all of the appropriate categories: 1. acceptable castings 2. castings requiring further fettling operations 3. scrap castings 4. castings requiring further inspection by supervision 7. Complete all of the following operations at shut-down: 1. close down any machinery or equipment used during the fettling 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
MPF2.23
Relevant Occupations
Engineering and Manufacturing Technologies, Manufacturing Technologies, Process Operatives, Process, Plant and Machine Operatives
SOC Code
8115
Keywords
Engineering; manufacturing; processing; fettling; metallic; casting; removing flash; polish; equipment; automated