5- AXIS CNC MACHINE OPERATION NC III COURSE

TESDA TRAINING REGULATIONS FOR 5- AXIS CNC MACHINE OPERATION NC III

The TESDA Course in 5-Axis CNC Machine Operation NC III consists of competencies that a person must achieve to write advance CNC program, set up machine, work piece and cutting tools and perform 5-axis CNC machine operations and conduct final inspection on work piece.

A student who has achieved this TESDA Course in 5- AXIS CNC MACHINE OPERATION NC III is competent to be:

• 5-Axis CNC Machine Programmer
• 5-Axis CNC Machine Operator
• CNC Lathe Machine Operator
• CNC Milling Machine Operator

TRAINEE ENTRY REQUIREMENTS

Trainees or students who wish to enter this training should possess the following requirements:

• Holder of any certificate of competency in Machining NC I or 1-Year industry experience in Machining
• Must have completed the 10-year basic education or an Alternative Learning System (ALS) Certificate of Completion with grade 10 equivalent holder
• Must have competence in CNC Lathe Machine and CNC Milling Machine Operation acquired through training or work experience or certification
• Can communicate orally and or in writing
• Can perform basic mathematical computation

5- AXIS CNC MACHINE OPERATION NC III COURSE MODULE

Course Title: 5- AXIS CNC MACHINE OPERATION
Level: NC III
Nominal Training Duration :

(Basic Competency) 40 hours
(Common Competency) 120 hours
(Core Competency) 272 hours

TOTAL DURATION: 432 Hours

This course is designed to enhance the knowledge, skill and attitudes of 5-AXIS CNC MACHINE OPERATION NC III in accordance with industry standards. This covers competencies that a person must achieve in writing 5-axis CNC machine program, setting-up 5-axis CNC machine, workpiece and cutting tools and performing pre and post 5-axis CNC machine operations.

Upon completion of the course, the learners are expected to demonstrate the above-mentioned competencies to be employed. To obtain this, all units prescribed for this qualification must be achieve.

COMPETENCIES REQUIRED IN 5- AXIS CNC MACHINE OPERATION NC III

This units of competency comprising this qualification include Basic, Common and Core Competencies.

To obtain this TESDA Course in 5- AXIS CNC MACHINE OPERATION NC III, all units prescribed below for this qualification must be achieved.

These units of competency comprising this qualification include the following:

UNIT CODE	CORE COMPETENCIES (272 hours)
MEE821321	Write 5-axis CNC machine program
MEE821322	Set-up 5-axis CNC machine, cutting tools and workpiece
MEE821323	Perform 5-axis CNC machine operations
MEE821324	Perform post 5-axis CNC machine operations
UNIT CODE	COMMON COMPETENCIES (120 hours)
MEE722201	Apply safety practices
MEE722202	Interpret working drawings and sketches
MEE722203	Select/ cut workshop materials
MEE722204	Perform shop computations (Basic)
MEE722205	Measure workpiece (Basic)
MEE722206	Perform routine housekeeping
MEE722207	Perform shop computations (Intermediate)
MEE722208	Measure workpiece using angular measuring instruments
MEE722210	Measure workpiece using gages and surface texture comparator
MEE722211	Perform preventive and corrective maintenance
ICT311201	Operate a personal computer
UNIT CODE	BASIC COMPETENCIES (40 hours)
400311319	Lead workplace communication
400311320	Lead small teams
400311321	Apply critical thinking and problem-solving techniques in the workplace
400311322	Work in a diverse environment
400311323	Propose methods of applying learning and innovation in the organization
400311324	Use information systematically
400311325	Evaluate occupational safety and health work practices
400311326	Evaluate environmental work practices
400311327	Facilitate entrepreneurial skills for micro-small-medium enterprises (MSMEs)

These guidelines are set to provide the Technical Vocational Education and Training (TVET) providers with information and other important requirements to consider when designing training programs for 5- AXIS CNC MACHINE OPERATION NC III.

CORE COMPETENCIES

UNIT OF COMPETENCY : WRITE 5-AXIS CNC MACHINE PROGRAM
UNIT CODE : MEE821321

This unit covers the knowledge and skills required to write 5-axis CNC program based on drawing specifications.

1. Determine job requirements
   • Drawings are interpreted to produce component according to specifications.
   • Sequence of CNC machining operations (tool pathing) are determined to produce component according to industry standard
   • Cutting tools are selected according to the requirements of the operations
   • Cutting speed and feed rate are calculated based on cutting tools and work piece specifications.
   • Process / operation sheets are filled up with relevant machine, work piece, fixture, tools and measuring instruments to be used.
   • Safety practices are applied according to OSHS.
2. Write 5-axis CNC machine program
   • Sequence of programs are generated using manual programing (G-codes /M-codes) and automatic programming using software according to standard operating procedure
   • Conversational or ISO CNC programming operations are used based on machine capability.
   • Safety practices are applied according to OSHS.
3. Edit 5-axis CNC program
   • Program is simulated and edited if required according to standard operating procedures
   • Program is saved to the machine file according to standard operating procedures
   • Proven program is copied and saved to backup program files according to standard operating procedures.
   • Safety practices are applied according to OSHS

UNIT OF COMPETENCY : SET UP 5-AXIS CNC MACHINE, CUTTING TOOLS AND WORK PIECE
UNIT CODE : MEE 821322

This unit covers the knowledge and skills required to set-up 5-axis CNC machine, cutting tools and workpiece.

1. Prepare machine
   • Power up machine according to manual operating procedure.
   • Oil and coolant level are checked according to manufacturers’ specification
   • Air and hydraulic pressure are checked according to manufacturers’ specification
   • Machine zero point is checked and set to required position according to standard operating procedure
   • Work holding and clamping devices are selected and mounted according to standard operating procedures.
   • Safety practices are applied according to OSHS
2. Prepare cutting tools
   • Cutting tools are selected according to required sequence of operation
   • Cutting tools are mounted on the designated tool holders according to standard operating procedure
   • Cutting tools are set-up according to the required length
   • Cutting tools with holders are mounted on the machine magazine/carousel according to tool number location
   • Safety practices are applied according to OSHS
3. Prepare workpiece
   • Work piece is mounted on clamping device to required level of accuracy using measuring tools and instruments/equipment in accordance with worksite procedures
   • Machine coordinate system (MCS) values are set to required position according to standard operating procedures
   • Workpiece coordinate system (WCS) values are set and verified to the required position according to standard operating procedures
   • Safety practices are applied according to OSHS

UNIT OF COMPETENCY : PERFORM 5-AXIS CNC MACHINE OPERATIONS
UNIT CODE : MEE 821323

This unit covers the knowledge and skills required to perform 5-AXIS CNC machining operations

1. Operate machine
   • Close machine guard according to safety standard operation procedures
   • Dry run is conducted in accordance with the desired tool path movement
     Program is edited according to tool path movement if required.
   • Operate 5 axis CNC machine to produce component to meet the desired dimensions, tolerance, fits, limits and surface finish according to job requirement.
   • Safety practices are applied according to OSHS.
2. Monitor machine and tool movements
   • Program parameters are checked based on computed data
   • Air pressure level is maintained according to machine operating manual
   • Cooling system is maintained according to viscosity requirements
   • Cutting tool sharpness is maintained according to work procedures
   • Safety practices are applied according to OSHS.
3. Check and measure work piece
   • Machine guard is opened according to machine operating manual
   • Work piece is cleaned and de burred while on the fixture according to standard operating procedure
   • Work piece is inspected and measured according to drawing specification
   • Safety practices are applied according to OSHS

UNIT OF COMPETENCY : PERFORM POST 5-AXIS CNC MACHINE OPERATIONS
UNIT CODE : MEE 821324

This unit covers the knowledge and skills required to perform post- 5-axis CNC machining operation.

1. Conduct post CNC operation
   • Work piece is unloaded from the fixture according to work instructions
   • Work piece is cleaned and de burred according to work instruction
   • Work piece is inspected and measured according to drawing specifications
   • Safety practices are applied according to OSHS
2. Submit work piece
   • Operator is sign out the operation sheet according to workplace procedures
   • Work piece and operation sheet are submitted to immediate supervisor according to work place procedures
   • Safety practices are applied according to OSHS
3. Shut-off machine and perform house keeping
   • Machine is shut-off according to manufacturer’s operating manual
   • Tools are maintained and stored based on established procedures
   • Defective tools and machines are tagged and reported according to work place procedures
   • Good housekeeping is performed following 5S
   • Wastes are disposed according to waste management procedures and environmental regulations
   • Safety practices are applied following OSHS

COMMON COMPETENCIES

UNIT OF COMPETENCY : APPLY SAFETY PRACTICES
UNIT CODE : MEE722201

This unit covers the competencies required to apply safety practices in the workplace.

1. Identify hazards
   • Hazards are identified correctly in accordance with OHS principles.
   • Safety signs and symbols are identified and adhered to.
2. Use protective clothing and devices
   • Appropriate protective clothing and devices correctly selected and used in accordance with OHS requirements or industry/ company policy.
3. Perform safe handling of tools, equipment and materials
   • Safety procedures for pre-use check and operation of tools and equipment followed in accordance with industry/ company policies.
   • Tools, equipment and materials handled safely in accordance with OHS requirements and industry/ company policies.
4. Perform first aid
   • First aid treatment of injuries are carried out according to recommended procedures.
5. Use fire extinguisher
   • Fire extinguisher selected and operated correctly according to the type of fire.

UNIT OF COMPETENCY : INTERPRET WORKING DRAWINGS And SKETCHES
UNIT CODE : MEE722202

This unit covers the competencies required to read and interpret drawings and sketches.

1. Interpret technical drawing
   • Components, assemblies or objects recognized as required.
   • Dimensions identified as appropriate.
   • Instructions identified and followed as required.
   • Material requirements identified as required.
   • Symbols recognized as appropriate in the drawing.
   • Tolerance, limits and fits identified in the drawing.
2. Prepare freehand sketch of parts
   • Sketch drawn correctly and appropriately.
   • Sketch depicted objects or part appropriately.
   • Dimensions indicated in sketch are clear and correct.
   • Instructions included in sketch are clear and correct.
   • Base line or datum points indicated as required.
3. Interpret details from freehand sketch
   • Components, assemblies or objects recognized as required.
   • Dimensions identified as appropriate.
   • Instructions identified and followed as required.
   • Material requirements identified as required.
   • Symbols recognized as appropriate in the drawing.

UNIT OF COMPETENCY : SELECT AND CUT WORKSHOP MATERIALS
UNIT CODE : MEE722203

This unit covers the skills and knowledge required to select and cut workshop materials.

1. Determine job requirement
   • Plans/ drawings are interpreted to produce component to specification.
   • Sequence of operation is determined to produce component to specification.
2. Select and measure materials
   • Materials are selected according to the requirement of the operation.
   • Materials are measured to required level of accuracy using measuring tools.
   • Measuring tools are used according to manufacturer’s specification.
3. Cut materials
   • Materials are cut according to plans/drawing instruction.
   • Cutting tools/ equipment are used based on manufacturers specification, appropriate techniques or the safety procedure.

UNIT OF COMPETENCY : PERFORM SHOP COMPUTATIONS (BASIC)
UNIT CODE : MEE722204

This unit covers the competencies required to perform
basic calculations using the four fundamental operation.

1. Perform four fundamental operations
   • Simple calculations are performed using four fundamental operations.
2. Perform basic calculations involving fractions and decimals
   • Simple calculations are performed involving fractions and decimals using the four fundamental operations.
   • Decimal are converted into fraction (and vice versa) accurately.
3. Perform basic calculations involving percentages
   • Simple calculations are performed to obtain percentages from information expressed in either fractional or decimal format.
4. Perform basic calculation involving ratio and proportion
   • Simple calculations are performed involving ratio and proportion using whole numbers, fractions and decimals.
5. Perform calculations on algebraic expressions
   • Simple calculations are performed on algebraic expressions using the four fundamental operations.
   • Simple transposition of formulae is carried out to isolate the variable required, involving the four fundamental operations.

UNIT OF COMPETENCY : MEASURE WORKPIECE (BASIC)
UNIT CODE : MEE722205

This unit covers the competencies required to measure workpieces using measuring instruments such as steel rule, Vernier caliper, micrometer, etc.

1. Select and use measuring tools
   • Measuring tools are selected and used according to the level of accuracy required.
   • Measurements taken are accurate to the finest graduation of the selected measuring instrument.
   • Measuring technique used is correct and appropriate to the device used.
2. Clean and store measuring tools
   • Care and storage of devices undertaken to manufacturer’s specifications or standard operating procedures.

UNIT OF COMPETENCY : PERFORM ROUTINE HOUSEKEEPING
UNIT CODE : MEE722206

This unit covers the competencies required to maintain an organized and clean work area.

1. Organize work area
   • Work area maintained in a safe, uncluttered and organized manner according to workshop policy.
   • All tasks carried out safely, effectively and efficiently with minimum inconvenience according to workshop policy.
   • Workshop policies and procedures for tidying work areas and placing items in designated areas applied.
2. Clean work area
   • Shop policies and procedures applied for cleaning work area.
   • Wastes promptly removed and disposed of according to shop policies and environmental requirements.
   • Spills, wastes and other potential hazards reported to appropriate personnel and removed according to shop policies and environmental requirements.
   • Signage promptly displayed in regard to unsafe areas.
   • Consumable

UNIT OF COMPETENCY : PERFORM SHOP COMPUTATIONS (INTERMEDIATE)
UNIT CODE : MEE722207

This unit covers the competencies required to perform calculation involving triangles and tapers.

1. Perform calculations involving triangles
   • Problems involving right triangles are performed using the trigonometric functions.
   • Problems involving non-right triangles are performed using sine and cosine rules.

UNIT OF COMPETENCY : MEASURE WORKPIECE USING ANGULAR MEASURING INSTRUMENTS
UNIT CODE : MEE722208

This unit covers the competencies required to measure workpieces using angular measuring instruments.

1. Select and use angular measuring tools
   • Angular measuring tools are selected and used according to the level of accuracy required.
   • Measurements taken are accurate to the finest graduation of the selected measuring instrument.
   • Measuring technique used is correct and appropriate to the device used.
2. Maintain angular measuring tools
   • Measuring tools are adjusted and maintained to the required accuracy utilizing manufacturer’s or worksite procedures.
3. Clean and store measuring tools
   • Care and storage of devices undertaken to manufacturer’s specifications or standard operating procedures.

UNIT OF COMPETENCY: MEASURE WORKPIECE USING GAGES AND SURFACE TEXTURE COMPARATOR
UNIT CODE: MEE722210

This unit covers the competencies required to measure workpieces using fixed and adjustable gages.

1. Select and use fixed and adjustable gages
   • Appropriate gages are selected and used to undertake the required comparison or measurement using standard operating procedures.
   • Consistent and accurate measurements obtained conforms to drawing specification
   • Measuring technique used is correct and appropriate to the device used.
2. Perform surface texture measurements
   • Surface texture are measured according worksite procedures.
   • Measurements taken are within the level of accuracy required.
3. Clean and store measuring tools
   • Care and storage of devices undertaken to manufacturer’s specifications or standard operating procedures

UNIT OF COMPETENCY : PERFORM PREVENTIVE AND CORRECTIVE MAINTENANCE
UNIT CODE : MEE722211

This unit covers the knowledge and skills required in performing preventive and corrective maintenance such as inspection and repair of hand tools, cleaning and lubrication of machine parts and changing drive pulley and belts.

1. Perform inspection of machine
   • Machine inspected according to worksite procedures.
   • Status/Report recorded on pro-forma or reported orally according to worksite procedure.
2. Perform cleaning and lubricating of machine
   • Machines lubricated as per manufacturer’s recommendation using appropriate tools and materials
   • Fluids and lubricants replaced and/or topped up according to prescribed schedule.
3. Perform minor machine repair and adjustments
   • Minor machine repairs performed according to manufacturer’s instruction or worksite procedures.
   • Machine moving parts adjusted to manufacturer’s specifications.
4. Maintain hand tools
   • Tool cutting ground to recommended specifications
   • Hand tools lubricated and stored according to prescribed procedure

UNIT OF COMPETENCY: OPERATE A PERSONAL COMPUTER
UNIT CODE: ICT311201

This unit defines the competency required to operate a personal computer by: starting the PC, logging in, using and working with files, folders and programs, saving work, and closing down the PC.

1. Start the computer
   • The peripheral devices are properly connected
   • Power is checked and the computer and peripheral devices are switched on
   • Proper logging in and logging off is successfully done
   • The operating system features and functions are accessed and navigated
   • Hardware configuration and other system features are checked
2. Arrange and customize desktop display/ Windows settings
   • The desktop screen or Windows elements are changed as needed
   • Desktop icons are added, renamed, moved, copied or deleted
   • The online help functions are accessed or used as needed
   • Desktop icons of application programs are selected, opened and closed
   • Properties of icons are displayed
   • Computer or desktop settings are saved and restored
3. Work with files and folders (or directories)
   • A file or folder is created, opened, moved, renamed or copied
   • Files are located, deleted and restored
   • Details and properties of files and folders are displayed or viewed
   • Various files are organized for easy lookup and use
   • Files and information are searched
   • Disks are checked, erased or formatted as necessary
4. Work with user application programs
   • Application programs are added, changed, removed or ran
   • User software or application program are installed, updated and upgraded
   • Information/data are moved between documents or files
5. Print information
   • Printer is added or installed and correct printer settings is ensured
   • Default printer is assigned accordingly
   • Information or document is printed on the installed printer
   • Progress of print jobs are viewed and deleted as required
6. Shut down computer
   • All open application programs are closed
   • Computer and peripheral devices are properly shut down

BASIC COMPETENCIES

The BASIC COMPETENCIES refer to non-technical skills (knowledge, skills and attitudes) that everybody will need in order to perform satisfactorily at work and in society and are considered portable and transferable irrespective of jobs and industrial settings.

LEAD WORKPLACE COMMUNICATION (400311319) – This unit covers the knowledge, skills and attitudes required to lead in the effective dissemination and discussion of ideas, information, and issues in the workplace. This includes preparation of written communication materials.

1. Communicate information about workplace processes
2. Lead workplace discussions
3. Identify and communicate issues arising in the workplace

LEAD SMALL TEAMS (400311320) – This unit covers the knowledge, skills and attitudes to lead small teams including setting, maintaining and monitoring team and individual performance standards.

1. Provide team leadership
2. Assign responsibilities
3. Set performance expectations for team members
4. Supervise team performance

APPLY CRITICAL THINKING AND PROBLE – SOLVING TECHNIQUES IN THE WORKPACE (400311321) – This unit covers the knowledge, skills and attitudes required to solve problems in the workplace including the application of problem solving techniques and to determine and resolve the root cause/s of specific problems in the workplace.

1. Examine specific workplace challenges
2. Analyze the causes of specific workplace challenges
3. Formulate resolutions to specific workplace challenges
4. Implement action plans and communicate results

WORK IN A DIVERSE ENVIRONMENT (400311322) – This unit covers the outcomes required to work effectively in a workplace characterized by diversity in terms of religions, beliefs, races, ethnicities and other differences.

1. Develop an individual’s cultural awareness and sensitivity
2. Work effectively in an environment that acknowledges and values cultural diversity
3. Identify common issues in a multicultural and diverse environment

PROPOSE METHODS OF APPLYING LEARNING AND INNOVATION IN THE ORGANIZATION (400311323) – This unit covers the knowledge, skills and attitudes required to assess general obstacles in the application of learning and innovation in the organization and to propose practical methods of such in addressing organizational challenges.

1. Assess work procedures, processes and systems in terms of innovative practices
2. Generate practical action plans for improving work procedures, processes
3. Evaluate the effectiveness of the proposed action plans

USE INFORMATION SYSTEMATICALLY (400311324) – This unit covers the knowledge, skills and attitudes required to use technical information systems, apply information technology (IT) systems and edit, format & check information.

1. Use technical information
2. Apply information technology (IT)
3. Edit, format and check information

EVALUATE OCCUPATIONAL SAFETY AND HEALTH WORK PRACTICES (400311325) – This unit covers the knowledge, skills and attitudes required to interpret Occupational Safety and Health practices, set OSH work targets, and evaluate effectiveness of Occupational Safety and Health work instructions

1. Identify OSH compliance requirements
2. Prepare OSH requirements for compliance
3. Perform tasks in accordance with relevant OSH policies and procedures

EVALUATE ENVIRONMENTAL WORK PRACTICES (400311326) – This unit covers the knowledge, skills and attitude to interpret environmental Issues, establish targets to evaluate environmental practices and evaluate effectiveness of environmental practices

1. Interpret environmental practices, policies and procedures
2. Establish targets to evaluate environmental practices
3. Evaluate effectiveness of environmental practices

FACILITATE ENTREPRENEURIAL SKILLS FOR MICRO-SMALL-MEDIUM ENTERPRISES (MSMEs) (400311327) – This unit covers the outcomes required to build, operate and grow a micro/small-scale enterprise.

1. Develop and maintain microsmall-medium enterprise (MSMEs) skills in the organization
2. Establish and maintain clientbase/market
3. Apply budgeting and financial management skills

DEFINITION OF TERMS

• 5-axis CNC (Computerized Numerical Control) Machine The automation of machine tools that are operated by precisely programmed commands encoded on a storage medium, as opposed to controlled manually via hand wheels or levers
• Machine coordinate system A point of reference in this system of coordinates is known as machine zero-point
• Work piece coordinate system A system of coordinates taking this point as reference is called the work piece coordinates system
• Machine Zero The position located at the farthest possible distance in a positive direction along the X-, Y-, and Z-axes. This position is permanently set for each particular CNC machine
• Micrometer A hand-held measuring device used to inspect the dimensions of parts. Thy typical micrometer is accurate within 0.001 in. or 0.02 mm
• Mode A machine state that determines the way it executes manual and automatic commands
• Optional Stop A code that pauses the program if the appropriate switch is selected on the machine. Optional Stop allows the operator to inspect the machine between operations
• Override A control that adjusts a programmed speed or feed rate by a certain percentage during operation
• Part Program A series of numerical instructions used by a CNC machine to perform the necessary sequence of operations to machine a specific work piece
• Part Programmer The person responsible for the creation of a part program. The part programmer translates the work piece design into program instructions for the CNC machine
• Proving Out Running a program one block at a time in order to check for accuracy and proper tool set-up
• Cycle Start The control used to begin a program or continue a program that has been previously stopped
• Cycle Stop The control used to pause a program. Cycle Stop pauses tool feed but does not stop spindle movement
• Dry Running Performing a trial run of the part program without any parts or cutting fluids to check the program
• Edit Mode The mode that allows an operator an operator to make changes to a part program and store those changes
• Emergency Stop The control that automatically shuts down all machine functions
• Feed rate Override An override that allows the operator to adjust the feed rate of the tool during operation. The override functions as a percentage of the programmed value
• Handle Mode The mode that allows for the manual operation of tool movement via the hand wheel. Some machines may have a combined handle/jog mode
• Rapid Feed Rate Override An override that allows the operator to reduce the rate of rapid tool movement during operation. A rapid override may be 25% of the original rate or less
• Rapid Mode The mode that allows for the manual movement of machine components at high rates of travel
• Tolerance The unwanted but acceptable deviation from a desired dimension
• Tool Offset A stored value that compensates for variations in tool length. Each tool requires an offset, which is measured from the turret or spindle position
• Zero return The control that automatically locates the turret or spindle in the machine zero position