FOUNDRY PATTERN MAKING NC II – TESDA COURSE MODULE

TESDA TRAINING REGULATIONS FOR FOUNDRY PATTERN MAKING NC II

The TESDA Course for FOUNDRY – PATTERN MAKING NC II consists of competencies that a person must achieve to be able to manufacture all types of solid, split and turned patterns and pattern component parts, including but is not limited to general engineering patterns, master patterns with multiple contraction, skeleton, frame and strickle, wheels, pulleys, chain sheaves, impellors, etc. It also include inspection, measurement and interpretation of drawings and repair procedures; setting up and operation of various specialized metalworking machines and utilization of precision measuring instrument in the operation and maintenance of melting equipment.

Patterns may be constructed by laminating timber and timber composites, stave and lag, box or frame construction or any alternative method that minimizes timber shrinkage, warp and achieves required strength. A full range of timber and timber composites may be used. Solid patterns may be set up on a regular or irregular joint.

Turned patterns are manufactured using tools and machines appropriate for shaping wood. This unit covers all specifications interpreted from drawings, technical sketches and/or customer requirements.

Tasks undertaken include utilizing appropriate wood pattern making principles and techniques, designated procedures, correct and appropriate tools and equipment.

This TESDA Qualification is packaged from the competency map of the Automotive Industry (Manufacturing sub-sector)

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

• Foundry Patternmaker

FOUNDRY PATTERN MAKING NC II – TRAINING AND REGULATION MODULE

Course Title: FOUNDRY PATTERN MAKING
Level: NC II
Nominal Training Duration : 158 Hours

This course is designed to enhance the knowledge, skills and attitudes of an individual in the field of foundry-pattern making in accordance with industry standards. It covers core competencies such as; develop and manufacture wood patterns, develop and manufacture polymer patterns, develop and manufacture assembled plated patterns, develop and manufacture polystyrene patterns, develop and manufacture production patterns, develop and manufacture vacuum forming moulds, develop and manufacture precision molds, develop and manufacture gear conveyor screw and propeller patterns, perform general woodworking machine operations, use and maintain measuring instrument.

This course is also designed to enhance the basic and common knowledge, skills and attitudes of an individual in the field of foundry-pattern making.

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 background in basic machining
• With good moral character;
• Ability to communicate both oral and written; and
• Physically and mentally fit

COMPETENCIES REQUIRED IN FOUNDRY PATTERN MAKING NC II

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

To obtain this TESDA course in FOUNDRY PATTERN MAKING 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 (120 Hours)
ALT742301	Develop and Manufacture Wood Patterns
ALT742302	Develop and Manufacture Polymer Patterns
ALT742303	Develop and Manufacture Assembled Plated Patterns
ALT742304	Develop and Manufacture Production Patterns
ALT742305	Performs General Woodworking Machine Operations
ALT821303	Use and Maintain Measuring Instrument
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

This section gives the details of the contents of the basic, common and core units of competency required in FOUNDRY PATTERNMAKING NC II.

CORE COMPETENCIES

UNIT OF COMPETENCY: DEVELOP AND MANUFACTURE WOOD PATTERN
UNIT CODE: ALT742301

This unit covers developing and manufacturing wood patterns, both regular shaped and split patterns, based on an understanding of casting and molding principles.

1. Determine job requirements
   • Job instructions and specifications are interpreted correctly.
   • Type of wood pattern required is determined through application of molding/casting techniques and foundry processes.
   • Appropriate timber/timber composites are selected to meet specification.
2. Develop and lay out wood patterns
   • Pattern parameters are calculated to specification e.g. angles, tapers, clearances, contractions etc.
   • Pattern is laid out showing tapers, machining allowances, core prints and method of construction to specification.
   • Jigs and fixtures are developed and manufactured to aid wood pattern manufacture as required
3. Manufacture wood patterns
   • Materials are marked out and construction is developed to meet specification.
   • Pattern or pattern component parts are produced to size and shape and checked for conformance to specifications using acceptable wood pattern making techniques and procedures and utilizing appropriate hand and handheld power tools.
   • Pattern component parts are joined or fixed as required and checked for conformance to specification. using acceptable wood pattern making techniques and procedures
   • Pattern is correctly marked, color-coded or tagged according to specifications or standard operating procedures.

UNIT OF COMPETENCY: DEVELOP AND MANUFACTURE POLYMER PATTERNS
UNIT CODE: ALT742302

This unit covers designing, manufacturing and finishing the polymer patterns.

1. Determine job requirements.
   • Job instructions and specifications are correctly interpreted and followed.
2. Inspect and prepare pattern
   • Patterns or cores are inspected for appropriate surface finish and set up on joint line or flat board to specification.
   • Appropriate parting agent is selected and applied to polymer specifications
3. Manufacture molds
   • Appropriate polymer materials are selected to specification.
   • Polymer and hardener are mixed to correct ratios and specifications using standard safety and operating procedures.
   • Polymer is applied to specification following predetermined methods such as ensuring air is not entrapped in application, excessive heat is not generated and de-lamination does not occur in final use.
   • Pattern/core box is stripped, inspected, cleaned and repaired as required.
   • Faces of polymer pattern are machined and finished to specifications.
   • Appropriate method of location is applied to patterns and core boxes.
   • Polymer tooling is checked for conformance to specifications as required.

UNIT OF COMPETENCY: DEVELOP AND MANUFACTURE ASSEMBLED PLATED PATTERNS
UNIT CODE: ALT742303

This unit covers assembling plated patterns.

1. Determine job requirement
   • Job instructions and specifications are correctly interpreted and followed.
2. Inspect and layout patterns
   • Pattern(s) are inspected to ensure dimensions and surface finish conforms to specifications.
   • Pattern and runner system is laid out to specifications from drawings, sketches or verbal instructions.
   • Pattern(s) alignment is correctly laid-out.
3. Mount pattern on plates
   • Cope and drag patterns/double-sided match plate patterns are attached to pattern plate/s according to specification.
   • Cope and drag patterns/double-sided match plate patterns are inspected for security and alignment.
4. Mount runner system
   • Volume of runner system conforms to specification.
   • All calculations are performed without error.
   • Runner components are attached to pattern plates using appropriate fixing and joining techniques using dowels and other fixing attachments to specification.
5. Inspect plated pattern assembly
   • Surface and mold-ability of plated pattern assembly are inspected and measured for compliance with specification

UNIT OF COMPETENCY: DEVELOP AND MANUFACTURE PRODUCTION PATTERNS
UNIT CODE : ALT742304

This unit covers developing pattern and manufacturing metal production patterns and core boxes.

1. Determine job requirements
   • Drawings, instructions and specifications are interpreted and understood.
   • Pattern type and design is conceptualized and planned with reference to customer’s specification (written or verbal) for number, layout, runner system and core box design.
   • Pattern design is interpreted and visualized from drawings, prints or plans and checked against customer requirements.
   • A plan is developed for sequence of manufacture for either a high or low volume foundry production pattern.
2. Manufacture production patterns and core boxes
   • Appropriate materials are selected and obtained to meet requirements of strength, durability and component finish etc.
   • Calculations appropriate to establishing pattern parameters are performed, including angles, tapers, contraction, etc. where applicable.
   • Appropriate machines and machining process are selected to shape/produce production patterns and core boxes to specification.
   • A range of hand and hand held power tools are selected to fashion/manufacture production patterns and core boxes to specification.
   • Production patterns and core boxes are checked to specification and surface finish and are checked for moldability.

UNIT OF COMPETENCY: PERFORM GENERAL WOODWORKING MACHINE OPERATIONS
UNIT CODE: ALT742305

This unit covers setting up and operating wood working machines used by engineering pattern makers and fabricators.

1. Determine job requirements
   • Job requirements, instructions and specifications are interpreted and understood.
   • Appropriate woodworking machine is selected to meet specifications.
2. Set up woodworking machines
   • Tools/cutters are selected appropriate to task requirements.
   • Cutting tools are sharpened and/or shaped to specification.
   • Tools/cutters are correctly installed using standard operating procedures.
   • Guards/stops are set and adjusted as required.
   • Woodworking machines are set-up in accordance with company standard operating procedures and safety requirements
3. Operate woodworking machines
   • Material to be machined is positioned and secured effectively.
   • Materials are machined to specification using standard operating procedures.
   • Material use is optimized and waste is minimized.
4. Check finished component
   • Machined component is checked against specifications and predetermined finish.

UNIT OF COMPETENCY: USE AND MAINTAIN MEASURING INSTRUMENT
UNIT CODE: ALT821303

This unit identifies the competence required to measure components or sections using non-specialist instrument and maintain the measuring instrument.

1. Measure dimensions or variables using appropriate instrument
   • Measurement of dimensions and variables are completed without causing damage to any instrument or components
   • Appropriate measuring instrument is selected
   • Relevant measuring techniques are used and results appropriately recorded
   • All measuring activities are carried out according to industry regulations/guidelines OHS & requirements and enterprise/procedures policies
2. Maintain measuring instrument
   • Maintenance of measuring instrument is achieved without causing damage to any instrument or component
   • Routine care and storage of measuring instrument is undertaken according to manufacture specifications
   • Checking and calibrating of measuring devices is done prior to use.
   • All maintenance activities of measuring instruments are carried out according to industry regulations/guidelines OHS legislation, and enterprise procedures policies

COMMON COMPETENCIES (AUTOMOTIVE MANUFACTURING)

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 drawings/specification
   • 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 (FOUNDRY)

• Alloy – An alloy is a homogeneous blend of two or more elements at least one of which is a metal, and where the resulting material as metallic properties.
• Carbon Dioxide – Carbon Dioxide Process consist of mixing a clean dry silica sand with a silicate binder, compacting the mixture to shape and hardening it by passing carbon dioxide gas.
• Casting – Casting is the term used to describe both the process and the product when molten metal is poured and solidified in a mold.
• Chemical Analysis – Analytical chemistry is the science that seeks ever improved means of measuring the chemical composition of natural and artificial materials.
• Cope – In a two-part mold, the cope is the name given to the top half of the pattern, flask, mold, or core.
• Core – The core is a sand shape that is inserted into the mold to produce the internal features of a casting, such as, holes or passages for water-cooling.
• Core Box – A core box is the mold or die used to produce casting cores.
• Core Print – The core print is the region added to the pattern, core, or mold that is used to locate and support the core within the mold.
• Draft – Draft is the taper on a pattern or casting that permits it to be withdrawn from the mold.
• Drag – The drag is the bottom part of the two-part mold.
• Dross – Dross is a mass of solid impurities floating on a molten metal bath. It appears usually on the melting of low melting point metals or alloys such as aluminum, copper, magnesium or each alloys.
• Fettle / Finishing – The process of cleaning the casting, removal of excess metal, grinding and inspection operation which may be required for some casting process.
• Flask – The flask is the box that contains the molding aggregate.
• Foundry – A Foundry is a factory which produces metal castings from either ferrous or non-ferrous alloys.
• Furnace – Furnaces are refractory lined vessels that contain the material to be melted and provide the energy to melt it.
• Gate – Gate is controlled entrances to the mold cavity.
• Gating System – Gating system is the network of channels used to deliver the molten metal to the mold cavity.
• Green Sand – The term Green Sand refers to that molded sand mixture which is allowed to remain moist and is used in casting ferrous and non-ferrous metals.
• Melting – The process includes melting the charge, refining the melt, adjusting the melt chemistry and tapping into a transport vessel. Refining is done to remove deleterious gasses and elements from the molten metal. Material is added during the melting process to bring the final chemistry within a specific range specified by industry and/or internal standards. During the tap, final chemistry adjustments are made.
• Molding – Is the process of making the mold cavity with a necessary allowances such as shrinkage, machining, taper, and surface finish. Usually it is done with green sand as the molding medium.
• Mold Cavity – The mold cavity is the shaped hole into which the molten metal is poured and solidified to produce the desired casting.
• Parting Line – Parting Line or Parting Surface is the interface that separates the cope and drag halves of a mold, flask, or pattern. The same part can also be found in some core making processes.
• Pattern – The pattern is the approximate copy of the final casting. The molding material (sand for sand molds) is then packed around the pattern and the pattern is removed to produce the mold cavity.
• Pattern Shrinkage Allowance – Dimensions added to the pattern to compensate for the solid shrinkage or contraction occurs in the solidified casting as it cools to room / ambient temperature.
• Pouring Cup – A Pouring Cup or Pouring Basin is the portion of the gating system that initially receives the molten metal from the pouring vessel and controls its delivery to rest of the mold.
• Refractories – Refers to materials that are used to make crucibles, linings for furnaces, kilns, ovens and incinerators. A practical requirement is the ability of the material to withstand temperatures above 1100oC without softening.
• Riser – A riser is an extra void created in the mold that will also fill with molten metal. It provides a reservoir of molten metal that flow into the mold cavity to compensate for any shrinkage during solidification.
• Runners – Runners are the horizontal part of the gating system that is connected to the gate.
• Slag – Are by-product of melting metals. They are composed of metal oxides and sulfides. The assist in melt temperature control and minimize oxidation of the liquid metal before casting.
• Sprue – From the pouring cup, the molten metal travels down the sprue the vertical part of the gating system that connects with the runners.
• Vents – Vents are additional channels providing an escape for the gasses that are generated within the mold.
• Wedge Chill Test – Indicates the chilling tendencies of cast iron melt which is related to melting conditions, chemical composition and casting section thickness.