FORGING NC II – TESDA COURSE MODULE

TESDA TRAINING REGULATIONS FOR FORGING NC II

The FORGING NC II consists of competencies that a person must achieve to be able to perform hand and hammer forging of low to medium carbon and alloy up to steel carbon and alloy steels using a variety of techniques, tools, formers and heating devices. It also include basic incidental heat/quenching, tempering and annealing of ferrous and non-ferrous metals of various types and thicknesses.

Forging is the term for shaping metal by using localized compressive forces. Cold forging is done at room temperature or near room temperature. Hot forging is done at a high temperature, which makes metal easier to shape and less likely to fracture. Warm forging is done at intermediate temperature between room temperature and hot forging temperatures. Forged parts can range in weight from less than a kilogram to 170 metric tons. Forged parts usually require further processing to achieve a finished part.

A student who has achieved this TESDA Course in FORGING NC II is competent to be:

• Blacksmith; or
• Hammer smith

FORGING NC II – TRAINING AND REGULATION MODULE

Course Title: FORGING
Level: NC II
Nominal Training Duration : 106 Hours

This course is designed to enhance the knowledge, skills and attitudes of an individual in the field of FORGING NC II Qualification. It consists of competencies that a person must achieve to be able to perform hand and hammer forging of low to medium carbon and alloy up to steel carbon and alloy steels using a variety of techniques, tools, formers and heating devices. It also include basic incidental heat/quenching, tempering and annealing of ferrous and non-ferrous metals of various types and thicknesses.

Basic competencies such as: Participate in workplace communication; Work in a team environment; Practice career professionalism; and Practice occupational health and safety are included.

It also includes common competencies such as: Read, Interpret and Apply Engineering Drawings; Perform Mensuration and Calculation Read; Interpret and Apply Specifications and Manuals and; Perform Shop Maintenance.

TRAINEE ENTRY REQUIREMENTS

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

• With 2 year experience in basic foundry melting
• Ability to communicate both orally and in writing; and
• Physically and mentally fit

COMPETENCIES REQUIRED IN FORGING NC II

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

To obtain this TESDA course in FORGING 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 (68 Hours)
ALT722301	Perform Hand Forging
ALT722302	Perform Hammer Forging
ALT722303	Perform Basic Incidental Heat/Quenching, Tempering and Annealing
UNIT CODE	COMMON COMPETENCIES (20 Hours)
ALT742201	Read & Interpret Engineering Drawings
ALT311202	Perform Mensuration and Calculation
ALT723203	Read, Interpret and Apply Specifications and Manuals
ALT723205	Perform Shop Maintenance
UNIT CODE	BASIC COMPETENCIES (18 Hours)
500311105	Participate in workplace communication
500311106	Work in a team environment
500311107	Practice career professionalism
500311108	Practice occupational health and safety procedures

CORE COMPETENCIES

UNIT OF COMPETENCY : PERFORM HAND FORGING
UNIT CODE : ALT722301

This unit covers using hand tools and formers, applying hand forging techniques and operating heat treatment equipment. The unit applies to hand forging low to medium carbon and alloy steels using a variety of techniques, tools, formers and heating devices.

1. Select material
   • Job requirements are determined from engineering drawing, job sheet or verbal instructions
   • Material calculations are made using volumes and weights that include provision for oxidization and shrinkage.
   • Material is selected according to the requirements of the job.
2. Use hand tools and formers
   • Hand tools and formers are selected for specific forging techniques.
   • Hand tools and formers are used according to the hand forging technique selected.
3. Operate heating equipment
   • Heating equipment is set up and operated in accordance with company procedures and/or manufacturer’s instruction.
   • Equipment is operated in a manner that minimizes oxidization.
   • Heat is controlled to specified areas.
4. Hand-forge articles
   • Hand forging technique is selected and applied according to the requirements of the job
   • Material is hand-forged to produce articles to specification.
   • Forging temperatures and heat specifications are adhered to for various materials.
   • Allowance is made for material shrinkage and oxidization based on the requirements of the job.

UNIT OF COMPETENCY : PERFORM HAMMER FORGING
UNIT CODE : ALT722302

This unit covers using hammer tools and formers, selecting material, and applying hammer forging techniques. The unit applies to the use of hammer forging techniques on carbon and alloy steels using various techniques, tools, formers, power hammers and heating devices. Equipment range does not include drop and upset machinery, vacuum furnaces or rolling and extruding mill machinery.

1. Select material
   • Job requirements are determined from engineering drawing, job sheet or verbal instructions
   • Material calculations are made using volumes and weights that include provision for oxidization and shrinkage.
   • Material is correctly selected for use with specific tools and formers.
2. Use hammer tools and formers
   • Hammer tools and formers are selected for specific forging technique.
   • Hammer tools and formers are used in accordance with the forging technique selected.
   • Forging machine is set up and operated in accordance with company procedures and/or manufacturer’s instruction.
3. Hammer-forge articles
   • Hammer forging technique is selected and applied according to the requirements of the job.
   • Material is hammer-forged to produce articles to specification
   • Defects are recognized and appropriate rectification action is taken.
   • Correct techniques are applied to the handling of hot metal with regard to balancing and pivoting.
   • Heating process is applied based on the material and/ or requirements of the job.

UNIT OF COMPETENCY : PERFORM BASIC INCIDENTAL HEAT/QUENCHING, TEMPERING AND ANNEALING
UNIT CODE : ALT722303

This unit covers performing straightforward heating/quenching, tempering and annealing of ferrous and nonferrous metals.
This unit applies to the heat treatment of ferrous and nonferrous metals of various types and thicknesses by a range of methods. These may include oxy acetylene, LPG gas equipment, forge etc. used to heat/quench, temper and anneal materials to specifications. Work would normally cover one-off processes or processes undertaken as incidental to trade work (e.g. tool making, metal spinning etc.)

1. Determine job requirements
   • Job requirements are determined from engineering drawing, job sheet or verbal instructions
2. Set up equipment for heat/quenching, tempering and annealing
   • Appropriate heating process and/or procedure are selected for the given job.
   • Equipment is set up according to standard operating procedures and manufacturers’ instructions.
3. Operate heating equipment
   • Safety procedures are observed in accordance with OH & S requirements.
   • Heating equipment is operated following standard operating procedures and/or manufacturer’s instructions.
   • Equipment adjustments are made in accordance with standard operating procedures and/or manufacturer’s instructions.
   • Material is heat-treated to achieve required result.

COMMON COMPETENCIES

UNIT OF COMPETENCY : READ, INTERPRET AND APPLY ENGINEERING DRAWINGS.
UNIT CODE : ALT742201

This unit deals with identifying, interpreting and applying specification from Engineering blue prints or drawings that provides the measurements of the product and pattern that is to be produced.

1. Identify and access engineering manuals / specifications
   • Appropriate Engineering drawings are identified and accessed as per job requirements.
   • Version and date of drawing is checked to ensure correct specification and procedure are identified.
2. Interpret drawings
   • Relevant dimensions and sections of the drawings/specifications are located in relation to the work to be conducted
   • Information in the manual are interpreted in accordance to industry practices
3. Apply information in the drawings & specifications
   • Engineering drawing is interpreted according to job requirements
   • Work steps are correctly identified in accordance with the specifications in the drawings.
   • Dimensional data and shape are applied according to the given task
4. Store drawings
   • The drawings and specification are stored properly to ensure prevention of damage, ready access and updating of information when required in accordance with company requirements

UNIT OF COMPETENCY : PERFORM MENSURATION AND CALCULATION
UNIT CODE : ALT311202

This unit includes identifying, caring for, handling, using and maintaining measuring instruments.

1. Select measuring instruments
   • Object or component to be measured is identified
   • Correct specifications are obtained from relevant source
   • Appropriate measuring instrument is selected according to job requirements
2. Carry out measurements and calculation
   • Measuring tools are selected in line with job requirements
   • Accurate measurements are obtained to job
   • Calculation needed to complete work tasks are performed using the four basic process of addition (+), subtraction (-), multiplication (x) and division (/).
   • Calculations involving fractions, percentages and mixed numbers are used to complete workplace tasks.
   • Numerical computation is self-checked and corrected for accuracy
   • Instruments are read to the limit of accuracy of the tool.
3. Maintain measuring instruments
   • Measuring instruments are kept free from corrosion
   • Measuring instruments are not dropped to avoid damage
   • Measuring instruments are cleaned before and after using.

UNIT OF COMPETENCY : READ, INTERPRET AND APPLY SPECIFICATION AND MANUALS.
UNIT CODE : ALT723203

This unit deals with identifying, interpreting and applying service specification manuals, maintenance procedure manuals and periodic maintenance manual.

1. Identify and access manual/specification
   • Appropriate manuals are identified and accessed as per job requirements.
   • Version and date of manual is checked to ensure correct specification and procedure are identified.
2. Interpret manuals
   • Relevant sections, chapters of manuals/specifications are located in relations to the work to be conducted
   • Information and procedure in the manual are interpreted in accordance to industry practices
3. Apply information in manual
   • Manual is interpreted according to job requirements
   • Work steps are correctly identified in accordance with manufacturer specification
   • Manual data is applied according to the given task
   • All correct sequencing and adjustments are interpreted in accordance with information contained on the manual or specifications
4. Store manuals
   • Manual or specification are stored appropriately to ensure prevention of damage, ready access and updating of information when required in accordance with company requirements

UNIT OF COMPETENCY : PERFORM SHOP MAINTENANCE
UNIT CODE : ALT723205

This unit deals with inspecting and cleaning of work area including tools, equipment and facilities. Storage and checking of tools/ equipment and disposal of used supplies/materials are also incorporated in this competency.

1. Inspect/clean tools and work area
   • Cleaning solvent used as per workshop/tools cleaning requirement
   • Work area is checked and cleaned
   • Wet surface/spot in work area is wiped and dried
2. Store/arrange tools and shop equipment
   • Tools/equipment are checked and stored in their respective shelves/location
   • Corresponding labels are posted and visible
   • Tools are safely secured and logged in the records
3. Dispose wastes/used lubricants
   • Containers for used lubricants are visibly labeled
   • Wastes/used lubricants are disposed as per workshop SOP
4. Report damaged tools/equipment
   • Complete inventory of tools/equipment is maintained
   • Damaged tools/equipment/facilities are identified and repair recommendation is given
   • Reports prepared has no error/discrepancy

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

UNIT OF COMPETENCY : DEVELOP CAREER AND LIFE DECISIONSUNIT OF COMPETENCY : PRACTICE  OCCUPATIONAL HEALTH AND SAFETY PROCEDURES
UNIT CODE : 500311108

This unit covers the outcomes required to comply with regulatory and organizational requirements for occupational health and safety.

1. Identify hazards and risks
   • Safety regulations and workplace safety and hazard control practices and procedures are clarified and explained based on organization procedures
   • Hazards/risks in the workplace and their corresponding indicators are identified to minimize or eliminate risk to co-workers, workplace and environment in accordance with organization procedures
   • Contingency measures during workplace accidents, fire and other emergencies are recognized and established in accordance with organization procedures
2. Evaluate hazards and risks
   • Terms of maximum tolerable limits which when exceeded will result in harm or damage are identified based on threshold limit values (TLV)
   • Effects of the hazards are determined
   • OHS issues and/or concerns and identified safety hazards are reported to designated personnel in accordance with workplace requirements and relevant workplace OHS legislation
3. Control hazards and risks
   • Occupational Health and Safety (OHS) procedures for controlling hazards/risks in workplace are consistently
     followed
   • Procedures for dealing with workplace accidents, fire and emergencies are followed in accordance with organization OHS policies
   • Personal protective equipment (PPE) is correctly used in accordance with organization OHS procedures and practices
   • Appropriate assistance is provided in the event of a workplace emergency in accordance with established organization protocol
4. Maintain OHS awareness
   • Emergency-related drills and trainings are participated in as per established organization guidelines and procedures
   • OHS personal records are completed and updated in accordance with workplace requirements

DEFINITION OF TERMS (FORGING)

• Forging – Forging is the term for shaping metal by using localized compressive forces
• Cold forging – Cold forging is done at room temperature or near room temperature.
• Hot forging – Hot forging is done at a high temperature, which makes metal easier to shape and less likely to fracture.
• Warm forging – Warm forging is done at intermediate temperature between room temperature and hot forging temperatures.
• Hammer forging – In modern times, industrial forging is done either with presses or with hammers powered by compressed air, electricity, hydraulics or steam. These hammers are large, having reciprocating weights in the thousands of pounds. Smaller power hammers, 500 lb (230 kg) or less reciprocating weight, and hydraulic presses are common in art smithies as well. Steam hammers are becoming obsolete.
• Open-die forging – Open-die forging is also known as smith forging. In open-die forging a hammer comes down and deforms the workpieces, which is placed on a stationary anvil. Open-die forging gets its name from the fact that the dies (the working surfaces of the forge that contract the workpiece) do not enclose the workpiece, allowing it to flow except where contacted by the dies. Therefore the operator needs to orient and position the workpiece to get the desired shape. The dies are usually flat in shape, but some have a specially shaped surface for specialized operations. For instance, the die may have a round, concave, or convex surface or be a tool to form holes or be a cut-off tool.
• Impression-die forging – Impression-die forging is also called closed-die forging. In impression-die work metal is placed in a die resembling a mold, which is attached to the anvil. Usually the hammer die is shaped as well. The hammer is then dropped on the workpiece, causing the metal to flow and fill the die cavities. The hammer is generally in contact with the workpiece on the scale of milliseconds. Depending on the size and complexity of the part the hammer may be dropped multiple times in quick succession.
• Flash Excess metal – is squeezed out of the die cavities; this is called flash. The flash cools more rapidly than the rest of the material; this cool metal is stronger than the metal in the die so it helps prevent more flash from forming. This also forces the metal to completely fill the die cavity. After forging the flash is trimmed off
• Press forging – Press forging is variation of drop-hammer forging. Unlike drop-hammer forging, press forges work slowly by applying continuous pressure or force. The amount of time the dies are in contact with the workpiece is measured in seconds (as compared to the milliseconds of drop-hammer forges). The press forging operation can be done either cold or hot.
• Upset forging – Upset forging increases the diameter of the workpiece by compressing its length. Based on number of pieces produced this is the most widely used forging process. A few examples of common parts produced using the upset forging process are engine valves, couplings, bolts, screws, and other fasteners.