CNC Set-up Prog - Milling And Turning (OKellers)
Competency-based
ONET: 51-4012.00
4
Years
162
Skills
907h
Related instructions
Classroom instruction topics
- Occupational Safety & Health for General Industry
- Basic Machining Processes
- Basic Computer Numerical Control (CNC)
- Manufacturing Processes
- Basic Mastercam
- Advanced Computer Numerical Control
- Advanced Mastercam
- Intro to Materials Science
- Mechanical Blueprint Reading with Sketching
- Geometric Dimensioning & Tolerance
- Intro to Engineering & Technology
- Technical Mathematics
- Intermediate Algebra for College Students
- Quality Planning and Team Building
- Coordinate Measuring Machine
- Machining Speeds and Feeds
On-the-job training
- Safety Compliance
- Demonstrate the ability to adhere to personal grooming and personal protective equipment requirements in the facility.
- Demonstrate the safe use of hand and power tools.
- Demonstrate the correct way to clean machines and floor area.
- Demonstrate the proper use of cleaning materials and fluids.
- Demonstrate OSHA lifting techniques.
- Identify all pinch points on primary and supportive machine tools and the proper placements of guards.
- Demonstrate both emergency and standard shut down of all required equipment.
- Demonstrate the proper use of a fire extinguisher.
- Lock-Out/Tag-Out
- Demonstrate adherence to performing lock-out/tag-out procedures and energy isolation for assigned machinery in accordance with facility regulations.
- Install blocking and trapping/or counter balance system
- Handling Hazardous Materials
- Demonstrate the ability to handle and store hazardous materials as assigned, while adhering to safe practices in accordance with OSHA and EPA requirements and guidelines, including completing the required documentation.
- When to implement spill control plan and demonstrate use of spill control kit
- Shop Practices
- Demonstrate the ability to know the jobs assigned to you.
- Demonstrate a working knowledge of the company policy manual.
- Demonstrate a dedication to the trade and to the quality and professional standards set forth by the company.
- Demonstrate an ability to show up on time every day with a desire to work hard and add value to the company.
- Demonstrate the ability to follow instructions laid out by your supervisor.
- Demonstrate the ability to maintain safe work habits in the exhibition of both one's personal responsibility for safety practices and displaying a continuous consideration of safety practices in the protection of one's fellow worker.
- Demonstrate the ability to maintain a clean orderly and safe work area.
- Identify the steps involved in 5S.
- Demonstrate how to perform a preventive maintenance procedure for a given machine to extend machine life and minimize downtime in accordance with company-approved maintenance specifications and overall program goals.
- Shop Mathematics
- Demonstrate how to convert fractions to decimals form.
- Demonstrate how to convert dimensions to metric equivalent.
- Demonstrate how to calculate a missing angle from a triangle.
- Demonstrate how to solve missing measurements in right angles.
- Demonstrate how to calculate the area of a circle.
- Demonstrate how to solve for the unknown hypotenuse of a right triangle using the Pythagorean Theorem.
- Blueprint Reading
- Demonstrate the ability to identify symbols, notations, and lines to industry standards.
- Demonstrate the ability to determine dimensions, critical features and tolerances on machine drawing.
- Demonstrate the ability to interpret pictorial drawings to industry standards.
- Demonstrate the ability to interpret multi-view drawings to industry standard.
- Metrology
- Demonstrate the ability to interpret part drawing specifications through working with blueprints (dimensions, layout, material, surface finish, countersinks, tolerances, threading, etc.).
- Demonstrate the use of measurement tools to inspect hole characteristics.
- Demonstrate the use of measurement tools to inspect thread characteristics.
- Demonstrate the use of measurement tools to inspect surface texture characteristics.
- Demonstrate the use of measurement tools to inspect hardness.
- Demonstrate the use of a steel rule.
- Demonstrate the use of ID and OD micrometers.
- Demonstrate the use of a height gauge.
- Demonstrate the use of a venier/dial caliper.
- Demonstrate the use of a pitch gage (thread gage).
- Demonstrate the use of a depth gage.
- Demonstrate the use of a Bore gage.
- Demonstrate the use of a Ring gage.
- Demonstrate the use of a Snap gage.
- Demonstrate the use of a Go/No-Go gage.
- Demonstrate the use of Jo Blocks.
- Demonstrate the use of a Pin gage.
- Demonstrate the use of a telescoping gage.
- Demonstrate the use of a Measuring scale.
- Demonstrate the use of a Radius gage.
- Demonstrate the use of a Tape measure.
- Demonstrate the use of a Taper gage.
- Demonstrate the use of a Ball gage.
- Measuring and Improving Work
- Demonstrate the ability to record points on a control chart.
- Demonstrate the ability to identify a process that is in or out of control.
- Demonstrate the ability to identify a production problem, propose a remedy, having been given the authorization to implement the process improvement and carry it out.
- Problem Solving
- Demonstrate the tracing of defects to the originating section of their root cause.
- Demonstrate the use of cause mapping when performing Root Cause Analysis.
- Demonstrate the ability to perform daily, weekly and monthly Preventative Maintenance responsibilities.
- Demonstrate the ability to conduct a triage level of troubleshooting and communicate findings to maintenance technician.
- Metal Cutting Fundamentals
- Demonstrate how adjusting cuttings can effect chip creation and cut conditions.
- Demonstrate the proper selection and installation of cutting tools to OD and ID toolholders.
- Demonstrate the proper workholding identification and set up for chucks, collets and vises.
- Demonstrate the correct selection and safe use of cutting fluids during the metal removal process.
- Demonstrate when to clamp and unclamp work piece for stress relief
- Demonstrate use of work supports, installation, and types (for milling & turning)
- Demonstrate how the properly set tool angles to meet part specifications for metal removal operations.
- Demonstrate how to calculate speeds and feeds for cutting tools.
- Demonstrate how to calculate tap drill size.
- Demonstrate how to identify wear on an insert.
- Manual Operations Tools and Techniques
- Demonstrate the safe and proper use of a bench vise.
- Demonstrate the safe and proper use of a ball-peened hammer.
- Demonstrate the safe and proper use of a soft faced hammer.
- Demonstrate the safe and proper use of a standard screw driver.
- Demonstrate the safe and proper use of a phillips screw driver.
- Demonstrate the safe and proper use of an offset screw driver.
- Demonstrate the safe and proper use of a hand hacksaw.
- Demonstrate the safe and proper use of a machinist's file.
- Demonstrate the safe and proper use of precision files.
- Demonstrate the safe and proper use of rotary and blur files.
- Demonstrate how to safely hand tap through tapering, plugging or bottoming.
- Demonstrate the safe and proper use of a T-handle wrench.
- Demonstrate the safe and proper use of a double-ended tap wrench.
- Demonstrate the safe and proper use of a tap extractor.
- Demonstrate how to thread dies.
- Demonstrate the safe and proper use of a solid hand reamer.
- Demonstrate the safe and proper use of an expansion hand reamer.
- Demonstrate the safe and proper use of an adjustable hand reamer.
- Demonstrate the safe and proper use of a roughing taper reamer.
- Demonstrate the safe and proper use of a finish taper reamer.
- Demonstrate how to prepare the layout table surface for metalwork.
- Demonstrate the safe and proper use of a pocket or double ended scribe.
- Demonstrate the safe and proper use of a combination square set.
- Demonstrate the safe and proper use of a surface gauge.
- Demonstrate the safe and proper use of a vernier height gauge.
- Demonstrate the safe and proper use of angular layout tools (bevel protractor head, rule, and universal bevel protractor).
- Demonstrate the safe and proper use of circular layout tools (dividers, trammels, center head and rule).
- Demonstrate the safe and proper use of permanent layout tools (pocket scribe, rule or straight edge, prick punch, automatic center punch).
- Demonstrate the safe and proper use of an angle plate.
- Demonstrate the safe and proper use of a toolmaker's clamp.
- Demonstrate the safe and proper use of a parallels.
- Demonstrate the safe and proper use of V-blocks.
- Demonstrate the safe and proper use of offset rules.
- Metal Removal Operations - Drilling Machines
- Demonstrate knowledge of drilling machine safety procedures, and the identification of drilling machine parts and their function.
- Demonstrate how to inspect and clean a drill press.
- Demonstrate how to drill and ream holes to specification.
- Demonstrate how to bore holes to specification.
- Demonstrate how to counter bore holes to specification.
- Demonstrate how to countersink holes to specification.
- Demonstrate how to spot face holes to specification.
- Demonstrate how to tap holes by industry standard.
- Metal Removal Operations - Metal Sawing Machines
- Demonstrate knowledge of sawing machine safety procedures, and the identification of sawing machine parts and their function.
- Demonstrate how to inspect and clean a metal cutting band saw.
- Demonstrate how to install a band saw blade, cut and weld.
- Demonstrate how to saw angles to specifications.
- Demonstrate how to saw contours to specifications.
- Demonstrate how to saw to scribed line within tolerance.
- Demonstrate how to saw straight cuts to specifications.
- Metal Removal Operations - Turning Operations
- Demonstrate knowledge of turning machine safety procedures, and the identification of turning machine parts and their function.
- Demonstrate how to perform proper cutting tool selection necessary to perform all required turning operations within the specified tolerances on a part print.
- Demonstrate the proper insert and tool holder selection, necessary to perform all required turning, and boring operations within the specified tolerances on a part print.
- Demonstrate how to set-up and carry out cutting internal and external tapers within the tolerances specified on a part print and taper calculations.
- Demonstrate how to calculate cutting speeds and feeds and apply these calculations while performing required, various turning operations on the lathe.
- Demonstrate how to select, mount, set-up, hold, and align work using work holding devices on the lathe to perform the required turning operations.
- Demonstrate how to perform turning, facing, necking, boring and grooving operations within the specified tolerances on the part print.
- Demonstrate how to perform square, angular, and filleted shouldering operations within the tolerances specified on a part print.
- Demonstrate how to cut an external and internal U.N. thread within the tolerances specified on the part print.
- Demonstrate how to cut an external and internal and taper on the engine lathe using the tailstock set-over method, compound rest, and a taper attachment to within the tolerances specified on a part print.
- Metal Removal Operations - Milling Operations
- Demonstrate knowledge of milling machine safety procedures, and the identification of milling machine parts and their function.
- Demonstrate how to perform proper cutting tool selection necessary to perform all required milling operations within the specified tolerances on a part print.
- Demonstrate how to properly select and insert the tool holder, necessary to perform all required milling operations within the specified tolerances on a blueprint.
- Demonstrate how to select, mount, set-up, hold, and align work using work holding devices on the milling machine to perform the required milling and squaring operations.
- Demonstrate how to calculate cutting speeds and feeds and apply these calculations while performing required milling, drilling, and boring operations on the milling machine.
- Demonstrate how to produce a part matching the milling process plan and the part print specifications.
- Metallurgy
- Explain how common grades of metals impact machining processes and apply the theory to the selection of tooling during machine set-up.
- List feeds and speeds associated with types of materials and selected tooling
- Machine selections
- Specialized Machining - EDM or Other
- Demonstrate knowledge of EDM machine safety procedures, and the identification of EDM machine parts and their function.
- Demonstrate how to perform proper wire electrode selection necessary to perform all required EDM operations within the specified tolerances on a part print.
- Demonstrate how to properly make clamp selection, necessary to perform all required EDM operations within the specified tolerances on a blueprint.
- Demonstrate how to produce a part matching the EDM process plan and the part print and current specifications.
- Controls
- Explain the Cartesian coordinate system and polar coordinates for a milling process.
- Explain the Cartesian coordinate system and polar coordinates for a turning process.
- Describe the functions and use of basic G and M codes.
- Demonstrate how to write a G code program in order to machine a basic cylindrical part on the CNC lathe.
- From a print of a basic cylindrical part, calculate the tooling, coordinates and toolpaths necessary to machine the part on a CNC lathe.
- Identify the canned cycles available on commonly used lathes in the work environment.
- Use of Macro programming
- Demonstrate how to write a G code program in order to machine a basic rectangular part on the CNC mill.
- From a print of a basic rectangular part with a pocket and threaded holes, calculate the tooling coordinates and toolpaths necessary to machine the part on a CNC mill.
- Identify the canned cycles available on commonly used mills in the work environment.
- Demonstrate how to make offsets to an existing CNC program, as required to meet part specifications.
- Demonstrate how to convert between different units of speed and feed variables required for the lathe.
- Demonstrate how to convert between different units of speed and feed variables required for the mill.
- Identify GD&T feature control frames.
- Identify standard GD&T dimensional tolerance.
- Identify GD&T tolerances for form orientation, location.
- Hydraulics
- Demonstrate adherence to safety, health and environmental rules and regulations for fluid power systems.
- Demonstrate how to interpret basic fluid power schematics, including identifying schematic symbols, process flow and operation of the components and system.
- Demonstrate how to start up and shut down a hydraulic system and adjust hydraulic pressure control valves in a system that uses a fixed displacement pump.
- Demonstrate how to select and adjust hydraulic actuator speed using a flow control valve.
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