CNC MILLING MACHINE OPERATION NC II – TESDA COURSE MODULE

TESDA TRAINING REGULATIONS FOR CNC MILLING MACHINE OPERATION NC II COURSE

The TESDA Course in CNC Milling Machine Operation NC II consists of competencies that a person must achieve to write basic CNC milling machine program, set-up machine, workpiece and cutting tools and perform basic CNC milling machine operations.

A student who has achieved this TESDA Course in CNC MILLING MACHINE OPERATION NC II is competent to be:

• CNC Milling Machine Operator (Basic)

TRAINEE ENTRY REQUIREMENTS

This section specifies the qualifications of trainees and their educational attainment. Other requirements like health and physical requirements are also stated. Passing entry written entrance examinations may also be indicated if necessary.

• Must be high school graduate
• With good moral character;
• Able to communicate in writing
• Physically and mentally fit; and
• Must have knowledge and skills in conventional milling machine operation and basic computer operation

CNC MILLING MACHINE OPERATION NC II – TRAINING AND REGULATION MODULE

Course Title: CNC MILLING MACHINE OPERATION
Level: NC II
Nominal Training Duration :

Basic Competencies – 18 hours
Common Competencies – 138 hours
Core Competencies – 80 hours

Total Duration: 236 Hours

This qualification is designed to develop knowledge, desirable attitudes and skills in CNC Milling Machine Operation NC II.

It covers the competencies required to write basic CNC milling program, set-up machine, workpiece and cutting tools and perform basic CNC milling machine operations.

COMPETENCIES REQUIRED IN CNC MILLING MACHINE OPERATION NC II

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

To obtain this TESDA course in CNC MILLING MACHINE OPERATION NC II, all units prescribed for this qualification must be achieved.

These units of competency comprising this qualification include the following:

UNIT CODE	CORE COMPETENCIES (138 Hours)
MEE821307	Write basic CNC milling machine program
MEE821308	Set-up CNC milling machine, workpiece and cutting tools
MEE821309	Perform basic CNC milling machine operations
UNIT CODE	COMMON COMPETENCIES (80 Hours)
MEE722202	Interpret working drawings and sketches
MEE722203	Select and cut workshop materials
MEE722204	Perform shop computations (Basic)
MEE722205	Measure workpiece (Basic)
MEE722207	Perform shop computations (Intermediate)
MEE722208	Measure workpiece using angular measuring instruments
MEE722211	Perform preventive and corrective maintenance
UNIT CODE	BASIC COMPETENCIES (20 Hours)
500311105	Participate in workplace communication
500311106	Work in a team environment
500311107	Practice career professionalism
500311108	Practice occupational health and safety procedures

This section gives the details and contents of the units of competency required in CNC MILLING MACHINE OPERATION NC II. These units of competency are categorized into basic, common and core competencies.

CORE COMPETENCIES

This section gives the details of the contents of the core units of competency required in CNC MILLING MACHINE OPERATION NC II.

UNIT OF COMPETENCY : Write Basic CNC Milling Machine Program
UNIT CODE : MEE821307

This unit covers the knowledge and skills required to write Basic CNC milling program.

1. Determine job requirements
   • Drawings are interpreted to produce component to specifications.
   • Sequence of operation is determined to produce component according to specification.
   • Cutting tools are selected according to the requirements of the operation.
   • Cutting speed and feed rate calculated based on workpiece and cutting tool material.
   • Process / job / adjustment sheets are filled up with relevant machine, tool and raw material data.
2. Write basic CNC milling machine program
   • Coordinates calculated for simple tool path or basic machining functions based on part or product to be produced.
   • Program written in standard CNC milling operations, code format in accordance with standard operating procedures.
3. Edit basic CNC milling programs
   • Program is simulated and edited according to standard operating procedures.
   • Program is saved to the machine according to standard operating procedures.
   • Program is downloaded to the machine according to standard operating procedures.(Optional)

UNIT OF COMPETENCY : Set-up CNC milling machine, workpiece and cutting tools
UNIT CODE : MEE821308

This unit covers the knowledge and skills required to set-up CNC milling machine and cutting tools, download program, set-up workpiece, dry-run program and perform trial cut on workpiece.

1. Set up machine and cutting tools
   • Oil and coolant is checked according to manufacturer’s specification.
   • Air and hydraulic pressure is checked according to manufacturer’s specification.
   • Machine zero point is set to the required position.
   • Cutting Tools are set according to required sequence of operations.
   • Workholding and clamping devices are tightened according to standard operating procedures.
   • Tool set-up is performed according to standard operating procedures.
2. Download/ inputed program
   • Program is downloaded/ inputed to the machine using appropriate devices.
   • Program is simulated to determine the correctness of the tool path and other work parameters.
   • Workpiece zero point is set to the required position.
3. Set-up workpiece
   • Workpiece is mounted on clamping device to required level of accuracy using tools and instruments / equipment in accordance with worksite procedures.
   • Set-up is performed in accordance with safety procedures and using personal protective devices.
4. Dry-run program
   • Dry run is performed in accordance with the desired tool path movement.
   • Where necessary, program is edited according to required tool path movement.
5. Perform trial cut on workpiece
   • Machined workpiece as programmed.
   • Checked and measured workpiece dimensions using appropriate measuring instruments.
   • Where required, program is edited and tool parameters are corrected/adjusted.

UNIT OF COMPETENCY : Perform Basic CNC Milling Machine Operations
UNIT CODE : MEE821309

This unit covers the skills required to operate CNC milling machine. It details the requirements for performing simple CNC milling operations such as drilling, boring, reaming, milling blocks, shoulder, parallel and angled faces, milling slots, keys, serrations, and milling castings and circular slots and external radius.

1. Mill workpiece
   • Workpiece is mounted or set in accordance with standard operating procedures.
   • Basic CNC Milling operations are performed to produce component as programmed.
     Corrective measures/adjustments are performed if necessary.
   • Safety procedures are observed during machining operation using personal protective devices.
   • Personal protective devices are used in accordance with occupational health and safety (OHS) requirements.
2. Check, and measure workpiece
   • Workpiece is checked and measured in conformance to specification using appropriate methods, measuring tools and equipment.
   • Defective workpieces are marked, recorded and reported for proper action.

COMMON COMPETENCIES

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 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 : 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

BASIC COMPETENCIES

UNIT OF COMPETENCY : PARTICIPATE IN WORKPLACE COMMUNICATION
UNIT CODE : 500311105

This unit covers the knowledge, skills and attitudes required to gather, interpret and convey information in response to workplace requirements.

1. Obtain and convey workplace information
   • Specific and relevant information is accessed from appropriate sources
   • Effective questioning, active listening and speaking skills are used together and convey information
   • Appropriate medium is used to transfer information and ideas
   • Appropriate non- verbal communication is used
   • Appropriate lines of communication with supervisors and colleagues are identified and followed
   • Defined workplace procedures for the location and storage of information are used
   • Personal interaction is carried out clearly and concisely
2. Participate in workplace meetings and discussions
   • Team meetings are at ended on time
   • Own opinions are clear expressed and those of others are listened to without interruption
   • Meeting inputs are consistent with the meeting purpose and established protocols
   • Workplace interactions are conducted in a courteous manner
   • Questions about simple routine workplace procedures and matters concerning working conditions of employment are asked and responded to.
   • Meetings outcomes are interpreted and implemented
3. Complete relevant work related documents
   • Range of forms relating to conditions of employment are completed accurately and legibly
   • Workplace data is recorded on standard workplace forms and documents
   • Basic mathematical processes are used for routine calculations
   • Errors in recording information on forms/documents are identified and properly acted upon
   • Reporting requirements to supervisor are completed according to organizational guidelines

UNIT OF COMPETENCY : WORK IN TEAM ENVIRONMENT
UNIT CODE : 500311106

This unit covers the skills, knowledge and attitudes to identify role and responsibility as a member of a team.

1. Describe team role and scope
   • The role and objective of the team is identified from available sources of information
   • Team parameters, reporting relationships and responsibilities are identified from team discussions and appropriate external sources.
2. Identify own role and responsibility within team
   • Individual role and responsibilities within the team environment are identified.
   • Roles and responsibility of other team members are identified and recognized.
   • Reporting relationships within team and external to team are identified.
3. Work as a team member
   • Effective and appropriate forms of communications used and interactions undertaken with team members who contribute to known team activities and objectives.
   • Effective and appropriate contributions made to complement team activities and objectives, based on individual skills and competencies and workplace context.
   • Observed protocols in reporting using standard operating procedures.
   • Contribute to the development of team work plans based on an understanding of team’s role and objectives and individual competencies of the members.

UNIT OF COMPETENCY : PRACTICE CAREER PROFESSIONALISM
UNIT CODE : 500311107

This unit covers the knowledge, skills and attitudes in promoting career growth and advancement.

1. Integrate personal objectives with organizational goals
   • Personal growth and work plans are pursued towards improving the qualifications set for the profession
   • Intra- and interpersonal relationships is are maintained in the course of managing oneself based on performance evaluation
   • Commitment to the organization and its goal is demonstrated in the performance of duties
2. Set and meet work priorities
   • Competing demands are prioritized to achieve personal, team and organizational goals and objectives.
   • Resources are utilized efficiently and effectively to manage work priorities and commitments
   • Practices along economic use and maintenance of equipment and facilities are followed as per established procedures
3. Maintain professional growth and development
   • Trainings and career opportunities are identified and availed of based on job requirements
   • Recognitions are sought/received and demonstrated as proof of career advancement
   • Licenses and/or certifications relevant to job and career are obtained and renewed

DEFINITION OF TERMS

• bench work the operations incident to the process of laying out, fitting, assembling, etc… when the work is placed on the bench or in a bench vise
• boring is the operation of enlarging a hole by means of an adjustable cutting tool with only one cutting edge
• chipping is the operation of removing/cutting metal using hammer and chisel
• counterboring is the operation of enlarging the end of a hole cylindrically
• facing the lathe operation of finishing the ends of the work, to
  make the piece the right length. Also known as squaring
• grinding refers to the removal of material from a workpiece with grinding wheel
• laying out term used to include the marking or scribbling of center points, circles, arcs, or straight lines upon metal surfaces, either curved or flat, for the guidance of the worker
• milling refers to removal of metal by feeding a workpiece through the periphery of rotating circular cutter
• reaming is an operation of sizing and finishing a hole by means of a cutting tool having several cutting edges. reaming serves to make the hole smoother, straighter, and more accurate
• spot-facing is the operation of smoothing and squaring the surface around a hole
• tapping is the operation of forming internal threads by means of a tool called tap
• turning refers to shaping a workpiece by gripping it in a work-holding device and rotating it under power against a suitable cutting tool
• CNC machining refers to the fabrication of work piece either turning, milling or any other machining process with the use of Computerized Numerically Controlled machine tools
• programming – the process of coding machining conditions in which information’s such as cutter dimensions, cutter movement, processing orders, federate or spindle speed all under fixed regulation or specified format which refers to the workpiece drawing to instruct Numerically Controlled machine tool
• CAD Computer Aided Design – the use of graphics-oriented computer software for designing and drafting applications
• CAM Computer Aided Manufacturing– computer software that generates programs for the operation of NC (numerical control) machine tools