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Setting CNC machine tools for operation

URN: SEMPAT323
Business Sectors (Suites): Engineering Woodworking, Pattern and Model Making Suite 3
Developed by: Enginuity
Approved on: 28 Feb 2018

Overview

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This standard identifies the competencies you need to prepare and set up computer numerically controlled (CNC) machine tools, such as milling, turning or electro discharge machines, in accordance with approved procedures. You will be expected to select the appropriate workholding devices to be used, and to mount and position them to the machine in the correct location for the type of operation being carried out. You will also be required to select the appropriate tools, cutters, electrodes or wires, to check them for defects, and to mount and secure them to the relevant tool holding devices and machine spindle.

You will need to ensure that all the tools have been allocated a relevant tool number, and that the relevant data on their co-ordinates and datum positions is entered into the operating program and machine. This will involve loading programs to the machine control, performing a 'dry run', proving the component program, checking for errors/faults, editing and saving program changes.

Your responsibilities will require you to comply with organisational policy and procedures for the machine-setting activities undertaken, and to report any problems with the equipment, tooling, programs or setting-up 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 the setting-up procedures used. You will understand the CNC machine used, and its application, and will know about the workholding devices, tooling, machine operating programs and setting-up procedures, in adequate depth to provide a sound basis for setting up the equipment, correcting faults and ensuring the work output is produced to the required specification.

You will understand the safety precautions required when working with the machine and its associated tools and equipment. 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:

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  1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
  2. follow the correct specifications for the component to be produced

  3. determine what has to be done and how the machine will be set to achieve this

  4. prepare the CNC machine for production

  5. position and secure the required workholding devices, work piece and cutting tools

  6. set the machine tool operating parameters to achieve the component specification
  7. check that all safety mechanisms are in place and that the equipment is set correctly for the required operations
  8. complete the required production documentation
  9. 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:

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  1. the specific safety precautions to be taken when setting up workholding devices and tooling on /CNC machines
  2. how to start and stop the machine in normal and emergency situations
  3. the importance of ensuring that the machine is isolated from the power supply before mounting cutting tools/electrodes and workholding devices
  4. the importance of wearing the appropriate protective clothing and equipment (PPE), and of keeping the work area clean and tidy
  5. the hazards associated with working on CNC machines (such as use of moving machinery, automatic machine operation, handling cutting tools, lifting and handling workholding devices, hot and airborne metal particles), and how they can be minimised
  6. how to handle and store cutting tools, electrodes/wires and programs, safely and correctly
  7. how to save the programs in the appropriate format, and the importance of storing programs and storage devices safely and correctly, away from contaminants and possible corruption
  8. the methods and procedures used to minimise the chances of infecting a computer with a virus
  9. the implications if the computer you are using does become infected with a virus and who to contact if it does occur
  10. 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)
  11. how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing
  12. the range of workholding methods and devices that are used on CNC machines
  13. why it is important to set the workholding device in relationship to the machine datums and reference points
  14. the methods of setting the workholding devices, and the tools and equipment that can be used
  15. the range of cutting tools or electrodes that are used on the CNC machines you are using, and typical applications of each
  16. how to check that the cutting tools or electrodes are in a safe and serviceable condition
  17. the use of tungsten carbide, ceramic and diamond indexible tip tooling, and the factors which will determine their selection and use (the condition of material supplied, hardness of the material, the cutting characteristics of the material, tolerances to be achieved, component surface finish and specifications)
  18. factors which affect the selection of electrodes or the type and size of wire to be used
  19. the various tool holding devices that are used, and the methods of correctly mounting and securing the cutting tools or electrodes to the tool holders
  20. the advantages of using pre-set tooling, and how to set the tooling using setting jigs/fixtures
  21. the use of magazines and carousels, and how to position and identify the tools in relationship to the operating program
  22. how to place the machine into the correct operating mode, and how to access the program edit facility in order to enter tooling data (such as tool datums, positions, lengths, offsets and radius compensation)
  23. how to conduct trial runs (using single-block run, dry run, and feed/speed override controls)
  24. the items that you need to check before allowing the machine to operate in full program run mode
  25. how the various materials will affect the feeds and speeds that can be used
  26. the application of cutting fluids with regard to a range of different materials, and why some materials do not require the use of cutting fluids
  27. typical problems that can occur with the setting up of the tooling and workholding devices, and what to do if such problems occur
  28. the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

Scope/range

Scope Performance

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1. Carry out all the following activities during setting up:
1.1. confirm the correct operating program has been loaded
1.2. check the tooling is in a usable condition
1.3. ensure the workpiece is correctly positioned and secured without distortion
1.4. update the program tool data as applicable
1.5. position and adjust machine guards
1.6. apply safe working practices at all times
1.7. leave the work area and machine in a safe and appropriate condition on completion of the activities

2. Prepare one of the following CNC machines in readiness for production:
2.1. turning
2.2. milling
2.3. spark erosion
2.4. wire erosion
2.5. machining centre

3. Position and secure work pieces using three of the following workholding methods and devices:
3.1. clamping direct to machine table
3.2. chucks with soft jaws
3.3. faceplates
3.4. vee blocks and clamps
3.5. collet chucks
3.6. indexing/rotating device
3.7. machine vice
3.8. jigs and fixtures
3.9. magnetic or pneumatic tables
3.10. chucks with hard jaws
3.11. angle plate
3.12. other specific workholding devices
 
4. Select and mount, in the appropriate tool holding device, the following types of tooling for the selected machine:
Either - Turning tools, to include six of the following:
4.1 turning
4.2 facing
4.3 twist/core drills
4.4 boring tools
4.5 reamer
4.6 thread-cutting tools
4.7 recessing/undercutting tools
4.8 profiling tools
4.9 taps
Or - Milling cutters, to include six of the following:
4.10 face mills
4.11 end mills
4.12 slot drills
4.13 twist/core drills
4.14 profile cutters
4.15 boring tools
4.16 reamers
4.17 taps
Or – Electrodes, to include two of the following, as applicable to the machine type:
4.18 plain electrodes
4.19 profile electrodes
4.20 hollow electrodes
4.21 wires

5.: Prepare the tooling for operation by carrying out all of the following activities, as applicable to the machine type:
5.1 manually or by using setting jigs/fixtures
5.2 positioning tools in the correct position in the machine head, turrets, magazine, carousel or docking station
5.3 loading and threading wire through wire-feed mechanism and wire guides
5.4 checking that tools, wires or electrode cartridge holders have a specific tool number or technology setting in relationship to the operating program
5.5 entering all relevant tool data to the operating program (tool lengths, tool offsets, radius compensation, wire type and size, number of skims)
5.6 setting tool or wire datum point
5.7 saving changes to program (as appropriate)

6. Set up the machine to produce pattern, corebox or model components, combining several different operations as follows for the selected machine:
Either – Turning, to include six of the following:
6.1 parallel diameters
6.2 tapered diameters
6.3 shoulders and steps
6.4 drilled holes
6.5 reamed holes
6.6 bored holes
6.7 internal threads
6.8 external threads
6.9 profiles
6.10 undercuts/recesses
6.11 flat faces
6.12 tapered bores
Or – Milling, to include six of the following:
6.13 flat faces
6.14 parallel faces
6.15 square faces
6.16 angular faces
6.17 drilled holes
6.18 reamed holes
6.19 bored holes
6.20 enclosed slots
6.21 open ended slots
6.22 special profiles
6.23 indexed or rotated forms
Or - Electro discharge machining, to include five of the following:
6.24 flat faces
6.25 tapered faces
6.26 angular faces
6.27 external profiles
6.28 internal profiles
6.29 slots
6.30 holes - linear (rows, angles)
6.31 holes on pitch circles
6.32 other special forms

7. Set the feeds and speeds appropriate to one of the following types of material:
7.1 carbon steel
7.2 stainless steel
7.3 non-metallic
7.4 cast iron
7.5 brass/bronze

8. Set the CNC machine to produce components to one of the following quality standards:
8.1 company
8.2 customer (contractual)
8.3 international

9. Complete the relevant data/documentation from one of the following, and pass it to the appropriate person:
9.1 job cards
9.2 production records
9.3 company specific documentation/computerised system

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

Skills

Glossary

Links To Other NOS

External Links

Version Number

2

Indicative Review Date

29 Apr 2021

Validity

Current

Status

Original

Originating Organisation

Semta

Original URN

SEMPAT23

Relevant Occupations

Engineering, Engineering and Manufacturing Technologies, Functional Managers, Managers and Senior Officials

SOC Code

5221

Keywords

engineering; woodworking; pattern making; model making; setting; CNC machine; CNC machine centre; CNC milling machine; CNC turning machine; CNC electro-discharge machine