TOOL AND DIE MAKING NC II – SCREED OPERATION NC I COURSE

TESDA TRAINING REGULATIONS FOR TOOL AND DIE MAKING NC II COURSE

The TESDA Course in Tool and Die Making NC II consists of competencies that a person must achieve to machine die components, fit and assemble dies and test and try die.

A student who has achieved this Course in TOOL AND DIE MAKING NC II is competent to be:

• Tool Maker, Die maker, Machinist

TOOL AND DIE MAKING NC II COURSE MODULE

Course Title: TOOL AND DIE MAKING
Level: NC II
Nominal Training Duration :

Total Training Duration 598 Hours

This qualification is designed to develop knowledge, desirable attitudes and skills in Tool and Die Making NC II.

It covers the competencies required to Machine Die Components, Fit and Assemble Dies and Test and Try Dies.

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.

• Must be a holder of Machining NC I or COC in BW, Turning, and Milling
• With good moral character
• Ability to communicate
• Physically and mentally fit

COMPETENCIES REQUIRED IN TOOL AND DIE MAKING NC II

This units of competency comprising this qualification include Basic, Common and Core Competencies. To obtain this course, all units prescribed for this qualification must be achieved.

UNIT CODE	CORE COMPETENCIES (Hours)
MEE722301	Machine Die Components
MEE722302	Fit and Assemble Dies
MEE722303	Test and Try Die
UNIT CODE	COMMON COMPETENCIES (Hours)
MEE722204	Perform shop computations (Intermediate)
MEE722205	Measure workpiece (Intermediate)
MEE722207	Perform preventive and corrective Maintenance
UNIT CODE	BASIC COMPETENCIES (18 Hours)
500311101	Receive and respond to workplace communication
500311102	Work with others
500311103	Demonstrate work values
500311104	Practice basic housekeeping procedures

This section gives the details of the contents of the core units of competency required in TOOL AND DIE MAKING NC II. These units of competency are categorized into basic, common and core competencies.

CORE COMPETENCIES

UNIT OF COMPETENCY : MACHINE DIE COMPONENT
UNIT CODE : MEE722301

This unit covers the knowledge and skills involved in the machining of die components such as die blocks, die plates and punches utilizing conventional turning, milling and grinding but does not cover non-conventional machine such as EDM and CNC machines

1. Determine job requirements
   • Drawings analyzed and cleared with designer for correct interpretation.
   • Job instructions clearly understood from superior as to what part to machine, and what to job out.
   • Materials to be used for each part with sufficient allowances listed.
   • Sequence of machining operations for each part determined according to work procedures
2. Machine die components
   • Plan sequence of operation for each part specifying equipment, tools, speeds and feeds requirement.
   • Die plate parts initially milled to requited dimensions, parallelity and squareness
   • Hole locations and die block hole opening and punch contours marked according the drawing.
   • Die parts of cylindrical section turned and finished to required dimension
   • Die parts of non-cylindrical sections milled to required shape according the drawing and specification.
   • Die block openings milled to slightly undersize dimensions to allow for final finishing and fitting operation.
   • Die parts are ground and finished according the specifications.
   • Die block, punch plate or pedestal punch drilled with assembly holes according drawing specifications.
3. Measure and check dimension
   • Dimensions and quality are checked for compliance to specifications.
   • Details and dimensional errors are identified against specification and reported to standard operation procedure (SOP).

UNIT OF COMPETENCY : FIT AND ASSEMBLE DIE
UNIT CODE : MEE722302

This unit covers the knowledge and skills in the fitting and assembly of simple blanking and piercing dies and bending dies and limited to 2-station progressive dies utilizing blanking and piercing, chop off and parting principle.

1. Determine die parts to be fitted with one another
   • Assembly drawings interpreted to determine which part to be fitted with another part.
   • Machined parts are checked to determine additional fitting or finishing work.
   • Fitting tools and equipment are identified according to fitting requirements.
2. Fit die parts
   • Template of product prepared as reference for finish filing.
   • Die holes are finish-filed to template size and required angle clearance
   • Stripper plate openings fitted with punches
3. Drill assembly holes
   • Die base assembled to bottom die holder according to work procedure.
   • Punch plate or punch pedestal drilled for mounting to punch holder according to work procedure
   • Stripper plate and punch plate and guide pin holes drilled and tapped according to work procedure.
   • Drilling operations of screw holes done according work procedure.
4. Assemble die
   • Die base assembled to bottom die holder according to work procedure.
   • Punch plate and pedestal punch mounted to punch holder according to work procedure
   • Fixed stripper plate mounted to die block or spring stripper mounted on punch plate as per drawing
   • Other parts assembled as required
   • Die tested for alignment as per work procedure
   • Adjustment made according to found errors
   • Dowel holes drilled according to work procedure

UNIT OF COMPETENCY : TEST AND TRY DIE
UNIT CODE : MEE722 303

This unit covers the knowledge and skills involved in the die setting and the press adjustment for the testing of dies and press run.

1. Prepare for testing of dies
   • Press checked for suitability to die shut off height.
   • Material strip or blank cut to required size or width and grain orientation.
2. Set up press and die
   • Die set on the bolster plate and punch shank inserted into ram hole and tightened.
   • Die set clamped on the bolster plate using the right tightening sequence.
   • Press ram adjusted to bottom dead center with the punch end to the required punch setting.
   • Press operated manually to check position of punch.
3. Operate press
   • Press started up safely and correctly.
   • Press operated according to standard procedure.
   • Material is loaded and the press is tripped for sample product.
4. Inspect product
   • Sample inspected for dimensional errors and deviations.
5. Rectify die
   • Die corrected according to deviations found and standard procedures

COMMON COMPETENCIES

UNIT OF COMPETENCY : PERFORM SHOP COMPUTATIONS
UNIT CODE : MEE722204

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

1. Perform calculations involving triangles
   • Problems involving right triangles performed using trigonometric functions
   • Problems involving non-right triangles performed using sine law and cosine law
2. Calculate tapers
   • Taper of work calculated correctly using appropriate formula

UNIT OF COMPETENCY : MEASURE WORKPIECE
UNIT CODE : MEE722205

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 according to the the level of accuracy required.
   • Measurements taken are accurate to the finest graduation of the selected measuring instrument.
   • Measuring technique used to correct and appropriate to the device used.
2. Maintain angular measuring tools
   • Measuring tools 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 yo manufacturer’s specifications or standard operating procedures

UNIT OF COMPETENCY : PERFORM PREVENTIVE AND CORRECTIVE MAINTENANCE
UNIT CODE : MEE722207

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 proforma 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 : RECEIVE AND RESPOND TO WORKPLACE COMMUNICATION
UNIT CODE : 500311101

This unit covers the knowledge, skills and attitudes required to receive, respond and act on verbal and written communication.

1. Follow routine spoken messages
   • Required information is gathered by listening attentively and correctly interpreting or understanding information/instructions
   • Instructions/information are properly recorded
   • Instructions are acted upon immediately in accordance with information received
   • Clarification is sought from workplace supervisor on all occasions when any instruction/information is not clear
2. Perform workplace duties following written notices
   • Written notices and instructions are read and interpreted correctly in accordance with organizational guidelines
   • Routine written instruction are followed in sequence
   • Feedback is given to workplace supervisor based on the instructions/information received

UNIT OF COMPETENCY : WORK WITH OTHERS
UNIT CODE : 500311102

This unit covers the skills, knowledge and attitudes required to develop workplace relationship and contribute in workplace activities.

1. Develop effective workplace relationship
   • Duties and responsibilities are done in a positive manner to promote cooperation and good relationship
   • Assistance is sought from workgroup when difficulties arise and addressed through discussions
   • Feedback provided by others in the team is encouraged, acknowledged and acted upon
   • Differences in personal values and beliefs are respected and acknowledged in the development
2. Contribute to work group activities
   • Support is provided to team members to ensure workgroup goals are met
   • Constructive contributions to workgroup goals and tasks are made according to organizational requirements
   • Information relevant to work is shared with team members to ensure designated goals are met

UNIT OF COMPETENCY : DEMONSTRATE WORK VALUES
UNIT CODE : 500311103

This unit covers the knowledge, skills, and attitude in demonstrating proper work values.

1. Define the purpose of work
   • One’s unique sense of purpose for working and the why’s of work are identified, reflected on and clearly defined for one’s development as a person and as a member of society.
   • Personal mission is in harmony with company’s values
2. Apply work values/ethics
   • Work values/ethics/concepts are classified and reaffirmed in accordance with the transparent company ethical standards, policies and guidelines.
   • Work practices are undertaken in compliance with industry work ethical standards, organizational policy and guidelines
   • Personal behavior and relationships with co-workers and/or clients are conducted in accordance with ethical standards, policy and guidelines.
   • Company resources are used in accordance with transparent company ethical standard, policies and guidelines.
3. Deal with ethical problems
   • Company ethical standards, organizational policy and guidelines on the prevention and reporting of unethical conduct are accessed and applied in accordance with transparent company ethical standard, policies and guidelines.
   • Work incidents/situations are reported and/or resolved in accordance with company protocol/guidelines.
   • Resolution and/or referral of ethical problems identified are used as learning opportunities.
4. Maintain integrity of conduct in the workplace
   • Personal work practices and values are demonstrated consistently with acceptable ethical conduct and company’s core values.
   • Instructions to co-workers are provided based on ethical, lawful and reasonable directives.
   • Company values/practices are shared with co-workers using appropriate behavior and language.

UNIT OF COMPETENCY : PRACTICE HOUSEKEEPING PROCEDURES
UNIT CODE : 500311104

This unit covers the knowledge, skills and attitudes required to apply the basic housekeeping procedures.

1. Sort and remove unnecessary items
   • Reusable, recyclable materials are sorted in accordance with company/office procedures
   • Unnecessary items are removed and disposed of in accordance with company or office procedures
2. Arrange items
   • Items are arranged in accordance with company/office housekeeping procedures
   • Work area is arranged according to job requirements
   • Activities are prioritized based on instructions.
   • Items are provided with clear and visible identification marks based on procedure
   • Safety equipment and evacuation passages are kept clear and accessible based on instructions
3. Maintain work area, tools and equipment
   • Cleanliness and orderliness of work area is maintained in accordance with company/office procedures
   • Tools and equipment are cleaned in accordance with manufacturer’s instructions/manual
   • Minor repairs are performed on tools and equipment in accordance with manufacturer’s instruction/manual
   • Defective tools and equipment are reported to immediate supervisor
4. Follow standardized work process and procedures
   • Materials for common use are maintained in designated area based on procedures
   • Work is performed according to standard work procedures
   • Abnormal incidents are reported to immediate supervisor
5. Perform work spontaneously
   • Work is performed as per instruction
   • Company and office decorum are followed and complied with
   • Work is performed in accordance with occupational health and safety (OHS) requirements

DEFINITION OF TERMS

• Press A machine by which pressure is applied to a workpiece to cut, pierce, bend or shape it
• Die A tool used to cut shaped blanks or holes; and bend and form metals into desired shape
• Blanking A press operation wherein shaped blanks are cut from metal by striking it with a punch against a die by a press.
• Bending A press operation that involves forming a metal part into a curved or angular shape, or the stretching or flanging of it along a curved path
• Drawing A press operation that forces plastic deformation of metal in a die to form recessed parts or cuplike shapes
• Drawing die A die that forms sheet metal into cuplike, wrinkle-free shapes
• Feed stock The raw material furnished to a press machine to form or shape the metal
• Trimming Removing excess materials from drawn or blanked part 9. Punching A piece (or a blank) is removed from a sheet metal or other material by a punch press
• Piercing Press – working where holes on metal is the desired output
• Ram A plunger, weight or other guided structure for exerting pressure by impact
• Tolerance A permissible deviation from a specified value, expressed in actual values or more often as a percentage of the nominal value
• Limits The maximum and minimum values prescribed for a specific dimension; the limits may be of size if dimension concerned is size dimension, or may be of location if the dimension concerned is a location dimension
• Fit The dimensional relationship between mating parts, such as press, shrink or sliding fit
• Die set – A set of lower and upper plate where the die assembly is set. The upper plate called the punch holder has bushings pressed into it that slides on guide posts pressed unto the lower plate called the die holder to maintain proper alignment of the members of the die
• Blanking punch – Is the part of the die that cuts or remove the blank from the strip.
• Piercing punch – Also called perforator, pierces holes through the blank. They are usually round and usually provided with a shoulder to retain them on a punch plate
• Punch plate – Plate which retains punches with their heads against the punch holder of the die set.
• Pilots – The part with acorn-shaped heads which enter previously pierced holes to shift the work before blanking occurs.
• Back gage – A thin member against which the material strip is held against by the operator (or pusher) in its travel through the die.
• Front plate – Similar to the back gage but shorter and placed opposite it . This is optional as other has none depending upon the construction of the fixed stripper
• Finger stop – Locates the lead end of the material strip at the first station of a progressive die
• Nesting – Pins or plate that locates a single blank in the die.
• Automatic stop – Locates the strip automatically while it is fed through the die.
• Stripper – Plate that removes the material strip from around the blanking and piercing punches during the upward movement of the die.
• Progressive die – A die in which the stock strip is advanced through a series of operations which work toward completion of a piece part.
• Advance Distance – The amount advanced by a strip for each stroke of the press. It is equal to the blank width plus the width of the scrap web (bridge) between blanks
• Stations – Basic divisions of a progressive die into which the stock strip is registered.
• Blank-through die – A die that produces a plain blank in one stroke of a press.