Producing pattern, corebox or model components using hand fitting techniques
Overview
This standard identifies the competencies you need to produce metal components to form pattern, corebox or model equipment 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 a range of 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 activities such as hand sawing, band sawing, filing, drilling, chiselling, threading, scraping, lapping and off- hand grinding. The components produced will have features from the following: 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 and non-ferrous, which may be in sheet form, bar sections (such as square/rectangular, round, hexagonal) 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 minimum 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 provide a good understanding of your work, and will provide an informed approach to applying hand-fitting procedures to produce metal parts for plated patterns and associated equipment or models. 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
- cut and shape the materials using appropriate methods and techniques
check that all the required shaping operations have been completed to the required specification
complete relevant data and 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:
- the health and safety requirements and safe working practices and procedures required for the hand fitting activities undertaken
- the importance of wearing appropriate protective clothing and equipment (PPE), and of keeping the work area safe and tidy
- the hazards associated with carrying out hand fitting techniques (such as use of power tools, trailing leads or hoses, damaged or badly maintained tools and equipment, using files with damaged or poor fitting handles), and how they can be minimised
- the procedure for obtaining the required drawings, job instructions and other related specifications
- how to use and extract information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS or ISO 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
- the cutting and shaping methods to be used, and the sequence in which the operations will need to be carried out
- how the properties of ferrous and non-ferrous metals affect the cutting, forming and shaping processes and the use of various tools (such as cutting speeds, angles)
- how to file flat, square and curved surfaces, and how to 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 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, internally)
- the types of files that are available, and the cut of files for different applications
- how to prepare the components for the filing operations (such as cleaning, de-burring, marking out)
- 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 that 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 are in a safe, tested and usable condition
- how to set and adjust 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 dimensionally-accurate marking out to specification and drawing requirements
- the company procedures for controlling documents and information
- the problems that can occur with the cutting and shaping operations, and how can these be overcome
- the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve
Scope/range
Scope Performance
Scope Knowledge
Values
Behaviours
You will be able to apply the appropriate behaviours required in the workplace to meet the job profile and overall company objectives, such as:
strong work ethic
positive attitude
- team player
- dependability
- responsibility
- honesty
- integrity
- motivation
- commitment