CNC MILLING MACHINE OPERATION NC III – TESDA COURSE MODULE

TESDA TRAINING REGULATIONS FOR CNC MILLING MACHINE OPERATION NC III COURSE

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

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

• CNC Milling Machine Operator (Advanced)

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
• Able to communicate in writing
• Physically and mentally fit ; and
• Must be a holder of CNC Milling Machine Operation NC II

CNC MILLING MACHINE OPERATION NC III COURSE MODULE

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

(Basic Competency) 24 hours
(Common Competency) 130 hours
(Core Competency) 80 hours

TOTAL DURATION: 234 Hours

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

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

COMPETENCIES REQUIRED IN CNC MILLING MACHINE OPERATION NC III

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

To obtain this TESDA Course in CNC MILLING 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 (80 hours)
MEE821310	Write advanced CNC milling machine program
MEE821311	Set-up multiple-axis CNC milling machine, workpiece and cutting tools
MEE821312	Perform advanced CNC milling machine operations
UNIT CODE	COMMON COMPETENCIES (130 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
MEE722209	Perform shop computations (Advanced)
MEE722210	Measure workpiece using gages and surface texture comparator
MEE722211	Perform preventive and corrective maintenance
MEE311212	Prepare cost estimates
UNIT CODE	BASIC COMPETENCIES (24 hours)
500311109	Lead Workplace Communication
500311110	Lead Small Teams
500311111	Develop and Practice Negotiation skills
500311112	Solve Problems Related to Work Activities
500311113	Use Mathematical Concepts and Techniques
500311114	Use Relevant Technologies

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 CNC MILLING MACHINE OPERATION NC III.

CORE COMPETENCIES

UNIT OF COMPETENCY : Write Advanced CNC Milling Machine Program
UNIT CODE : MEE821310

This unit covers the skills required to write complex programs for CNC milling machine with 3 or more axes.

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 advanced CNC milling machine program
   • Coordinates calculated for complex tool path or advanced 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 advanced CNC milling machine 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 multiple-axis CNC milling machine, workpiece and cutting tools
UNIT CODE : MEE821311

This unit covers the knowledge and skills required to set-up CNC milling machine with 3 or more axes 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.
   • 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 Advanced CNC Milling Machine Operations
UNIT CODE : MEE821312

This unit covers the skills required to operate CNC milling machine with 3 or more axes. It details the requirements for performing complex 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 externa/internal radius.

1. Mill workpiece
   • Workpiece is mounted or set in accordance with standard operating procedures.
   • Complex 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 : 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: PERFORM SHOP COMPUTATIONS (ADVANCED)
UNIT CODE: MEE722209

This unit covers the competencies required to perform calculation involving gear ratio, indexing problems and gearing problems.

1. Calculate gear ratio
   • Gear ratio calculated using appropriate formula
2. Solve indexing problems
   • Indexing problems involving number of turns, spaces and circle plate are solved using appropriate formula
3. Solve gearing problems
   • Gearing problems are solved using appropriate formula
4. Use geometrical principles in the solution of problems
   • Solution to problems is obtained by applying geometrical properties of angles, triangles and circles in the calculation.

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: PREPARE COST ESTIMATES
UNIT CODE : MEE311212

This unit covers the outcomes required to calculate costs for a particular job order/request in a machine-shop or metal-working environment.

1. Determine customer requirements
   • Plans/ drawings are interpreted to produce component to specifications.
   • Cost-effective sequence of operations to produce component to specifications is determined in accordance with worksite policies.
   • Where available, sample part or product is inspected for parameters relevant to cost determination.
   • Materials are determined according to the job requirements.
   • Additional details of job are obtained through discussion with customer or from information supplied.
   • Where applicable, client is advised on the feasibility and cost-effectiveness of the production job based on the constraints/capabilities of the machine and current market prices.
2. Estimate cost components
   • Cost components are calculated based on job requirements and worksite procedures.
   • Where necessary data on current costs are verified with the current market price.
   • Appropriate personnel are consulted with regard to additional data for costing.
3. Cost the job
   • Costing is set at optimal and affordable levels based on customer requirements and worksite procedures.
   • Where necessary, initial/rough cost estimate is provided to client following worksite procedures.
   • Total production costs are determined and finalized in accordance with worksite procedures.
4. Verify and document costs
   • Cost quotations are finalized and cleared with personnel concerned.
   • Costing details are documented and filed for future reuse or reference based on worksite procedures.

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.

UNIT OF COMPETENCY : LEAD WORKPLACE COMMUNICATION
UNIT CODE : 500311109

This unit covers the knowledge, skills and attitudes required to lead in the dissemination and discussion of ideas, information and issues in the workplace.

1. Communicate information about workplace processes
   • Appropriate communication method is selected
   • Multiple operations involving several topics areas are communicated accordingly
   • Questions are used to gain extra information
   • Correct sources of information are identified
   • Information is selected and organized correctly
   • Verbal and written reporting is undertaken when required
   • Communication skills are maintained in all situations
2. Lead workplace discussions
   • Response to workplace issues are sought
   • Response to workplace issues are provided immediately
   • Constructive contributions are made to workplace discussions on such issues as production, quality and safety
   • Goals/objectives and action plan undertaken in the workplace are communicated
3. Identify and communicate issues arising in the workplace
   • Issues and problems are identified as they arise
   • Information regarding problems and issues are organized coherently to ensure clear and effective communication
   • Dialogue is initiated with appropriate personnel
   • Communication problems and issues are raised as they arise

UNIT OF COMPETENCY : LEAD SMALL TEAMS
UNIT CODE : 500311110

This unit covers the knowledge, skills and attitudes to lead small teams including setting and maintaining team and individual performance standards.

1. Provide team leadership
   • Work requirements are identified and presented to team members
   • Reasons for instructions and requirements are communicated to team members
   • Team members’ queries and concerns are recognized, discussed and dealt with
2. Assign responsibilities
   • Duties, and responsibilities are allocated having regard to the skills, knowledge and aptitude required to properly undertake the assigned task and according to company policy
   • Duties are allocated having regard to individual preference, domestic and personal considerations, whenever possible
3. Set performance expectations for team members
   • Performance expectations are established based on client needs and according to assignment requirements
   • Performance expectations are based on individual team members duties and area of responsibility
   • Performance expectations are discussed and disseminated to individual team members
4. Supervised team performance
   • Monitoring of performance takes place against defined performance criteria and/or assignment instructions and corrective action taken if required
   • Team members are provided with feedback, positive support and advice on strategies to overcome any deficiencies
   • Performance issues which cannot be rectified or addressed within the team are referenced to appropriate personnel according to employer policy
   • Team members are kept informed of any changes in the priority allocated to assignments or tasks which might impact on client/customer needs and satisfaction
   • Team operations are monitored to ensure that employer/client needs and requirements are met
   • Follow-up communication is provided on all issues affecting the team
   • All relevant documentation is completed in accordance with company procedures

UNIT OF COMPETENCY : DEVELOP AND PRACTICE NEGOTIATION SKILLS
UNIT CODE : 500311111

This unit covers the skills, knowledge and attitudes required to collect information in order to negotiate to a desired outcome and participate in the negotiation.

1. Plan negotiations
   • Information on preparing for negotiation is identified and included in the plan
   • Information on creating non verbal environments for positive negotiating is identified and included in the plan
   • Information on active listening is identified and included in the plan
   • Information on different questioning techniques is identified and included in the plan
   • Information is checked to ensure it is correct and up-to- date
2. Participate in negotiations
   • Criteria for successful outcome are agreed upon by all parties
   • Desired outcome of all parties are considered
   • Appropriate language is used throughout the negotiation
   • A variety of questioning techniques are used
   • The issues and processes are documented and agreed upon by all parties
   • Possible solutions are discussed and their viability assessed
   • Areas for agreement are confirmed and recorded
   • Follow-up action is agreed upon by all parties

UNIT OF COMPETENCY : SOLVE PROBLEMS RELATED TO WORK ACTIVITIES
UNIT CODE : 500311112

This unit of 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 of problems.

1. Identify the problem
   • Variances are identified from normal operating parameters; and product quality
   • Extent, cause and nature are of the problem are defined through observation, investigation and analytical techniques
   • Problems are clearly stated and specified
2. Determine fundamental causes of the problem
   • Possible causes are identified based on experience and the use of problem solving tools / analytical techniques.
   • Possible cause statements are developed based on findings
   • Fundamental causes are identified per results of investigation conducted
3. Determine corrective action
   • All possible options are considered for resolution of the problem
   • Strengths and weaknesses of possible options are considered
   • Corrective actions are determined to resolve the problem and possible future causes
   • Action plans are developed identifying measurable objectives, resource needs and timelines in accordance with safety and operating procedures
4. Provide recommendation/s to manager
   • Report on recommendations are prepared
   • Recommendations are presented to appropriate personnel.
   • Recommendations are followed-up, if required

UNIT OF COMPETENCY : USE MATHEMATICAL CONCEPTS AND TECHNIQUES
UNIT CODE : 500311113

This unit covers the knowledge, skills and attitudes required in the application of mathematical concepts and techniques.

1. Identify mathematical tools and techniques to solve problem
   • Problem areas are identified based on given condition
   • Mathematical techniques are selected based on the given problem
2. Apply mathematical procedure/solution
   • Mathematical techniques are applied based on the problem identified
   • Mathematical computations are performed to the level of accuracy required for the problem
   • Results of mathematical computation is determined and verified based on job requirements
3. Analyze results
   • Result of application is reviewed based on expected and required specifications and outcome
   • Appropriate action is applied in case of error

UNIT OF COMPETENCY : USE RELEVANT TECHNOLOGIES
UNIT CODE : 500311114

This unit of competency covers the knowledge, skills, and attitude required in selecting, sourcing and applying appropriate and affordable technologies in the workplace.

1. Study/select appropriate technology
   • Usage of different technologies is determined based on job requirements
   • Appropriate technology is selected as per work specification
2. Apply relevant technology
   • Relevant technology is effectively used in carrying out function
   • Applicable software and hardware are used as per task requirement
   • Management concepts are observed and practiced as per established industry practices
3. Maintain/enhance relevant technology
   • Maintenance of technology is applied in accordance with the industry standard operating procedure, manufacturer’s operating guidelines and occupational health and safety procedure to ensure its operative ability
   • Updating of technology is maintained through continuing education or training in accordance with job requirement
   • Technology failure/ defect is immediately reported to the concern/responsible person or section for appropriate action

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
• counter boring is the operation of enlarging the end of a hole cylindrically
• drilling is the operation of producing a circular hole by removing solid metal 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 scribling 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