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The National Institute for Metalworking Skills, Inc.

Duties and Standards For

Machining Skills-Level III NIMS/ANSI 101-2001

Developed By:

Copyright July 1997-Revised September 2001 Distributed by: The National Institute for Metalworking Skills, Inc 3251 Old Lee Highway Fairfax, VA 22030 1-703-352-4971 Fax 1-703-352-4991 www.nims-skills.org

Duties and Standards

for

Machining Skills--Level III

i.

Table of Contents Occupational Description and Benchmarks .................................................................................... 3

Occupational Description.................................................................................................... 3 Bench Skills ........................................................................................................................ 3 Metal Cutting Skills ............................................................................................................ 3 Inspection and Quality Assurance Skills ............................................................................ 3 Other Skills and Competencies ........................................................................................... 4

Framework for Machining Skills—Level III .................................................................................. 5 Duty Area: 1. Job Planning and Management ................................................................................ 7

Duty: 1.1 Job Process Planning...................................................................................... 7 Duty Area: 2. Job Execution ........................................................................................................... 9

Duty: 2.1 Bench Operations: Hand Lapping................................................................... 9 Duty: 2.2 Angle Contour Bandsawing.......................................................................... 11 Duty: 2.3 Turning Operations: Manual Contour Turning............................................ 13 Duty: 2.4 Turning Operations: Steady Rest Turning and Boring ................................ 15 Duty: 2.5 Turning Operations: Follower Rest Turning................................................ 17 Duty: 2.6 Turning Operations: Difficult Materials ...................................................... 19 Duty: 2.7 Milling: Mill Compound Angles .................................................................. 21 Duty: 2.8 Milling: Manual Contour Milling ................................................................. 23 Duty: 2.9 Horizontal Boring Mill: Line Boring............................................................ 25 Duty: 2.10a Grinding: Select, Inspect, Set up, and Balance Wheels ................................ 27 Duty: 2.10b Grinding: Tapered Cylindrical Grinding ...................................................... 29 Duty: 2.11 Grinding: Grind I.D. and O.D. Surfaces ....................................................... 31 Duty: 2.12 Grinding: Grind Tapers on an Universal Grinder ......................................... 33 Duty: 2.13 Grinding: Contour Grinding ......................................................................... 35 Duty: 2.14 EDM: Operate a 4 Axis Wire EDM.............................................................. 37 Duty: 2.15 CNC: Advanced Manual RS-274-D Programming ...................................... 39 Duty: 2.16 CNC: Use Manufacturing Modeling Software to Create RS-274-D Programs...................................................................................... 41 Duty: 2.17 CNC: Milling Centers ................................................................................... 43 Duty: 2.18 CNC: Turning Centers .................................................................................. 45 Duty: 2.19 CNC: Turning Centers with Secondary Milling ......................................... 47

Knowledge, Skills, Abilities and Other Characteristics KSAO Area: 2. Mathematics ................................................................................................ 49

KSAO: 2.1 Geometry of Compound Angles, Profiles of a Line, and Profile of a Surface .................................................................... 49

KSAO Area: 3. Computer Aided Manufacturing Technology ............................................. 50

KSAO:3.1 Computer Aided Manufacturing Software.................................................. 50

APPENDIX A Cross-References to Machining Skills—Level I & II .................................... 51 Cross-References to Machining Skills—Level I KSAO Area: 1. Written and Oral Communication ................................................................. 52

KSAO: 1.1 Reading ....................................................................................................... 52 KSAO: 1.2 Writing ........................................................................................................... 54

KSAO: 1.3 Speaking...................................................................................................... 56 KSAO: 1.4 Listening...................................................................................................... 58

KSAO Area: 3. Decision Making and Problem Solving ....................................................... 60

KSAO: 3.1 Applying Decision Rules ............................................................................ 60 KSAO: 3.2 Basic Problem Solving................................................................................ 62

KSAO Area: 4. Group Skills and Personal Qualities.............................................................. 63

KSAO: 4.1 Group Skills ................................................................................................ 63 KSAO: 4.2 Personal Qualities ....................................................................................... 65

Cross-References to Machining Skills—Level II KSAO Area: 3. Engineering Drawings and Sketches.............................................................. 66

KSAO: 3.1 Isometric and Orthographic Sketching.......................................................... 66 KSAO: 3.2 Interpreting Engineering Drawings: Geometric Dimensioning and

Tolerancing........................................ ........................................... 67 KSAO: 3.3 Interpreting Engineering Drawings: Auxiliary Views ................................. 68

KSAO Area: 4. Measurement .................................................................................................... 69

KSAO: 4.1 Manual Coordinate Measuring Machines ...................................................... 69 APPENDIX A National Institute for Metalworking Skills, Inc-Executive Committee ............. 70 APPENDIX B National Institute for Metalworking Skills, Inc. Board of Directors.................. 71

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Machining Skills—Level III Occupational Description and Benchmarks for Machining Skills—Level III

Occupational Description

Machining Skills—Level III are used by skilled tradespersons who have achieved proficiency in the core competencies of Machining Skills I and II and have advanced to higher levels of technical competency or have developed new competencies. The general areas of competency remain:

• Bench skills • Metal cutting skills • Inspection and quality assurance skills

Machining Skills—Level III applies to both single part and multiple part production. A person who has achieved Machining Skills III competency may have modest supervision responsibilities for other operators or production workers. Additionally, people who have achieved Skills III competence will be called upon to provide training for machining technicians.

Bench skills

• Lay out of hole locations on bolt circles, angular surfaces, profiles of a line and points of tangency.

• Read and comprehend complex orthographic blueprints using geometric dimensioning and tolerancing symbology.

• Read and comprehend blueprints that have multiple auxiliary views. • Hand lap small surfaces.

Metal cutting skills:

• Use indexing devices to locate part features. • Produce compound angled and irregular surfaces. • Produce work to close tolerances. • Set up and operate a boring mill. • Set up and operate a cylindrical grinder. • Set up and operate CNC machine tools. • Improve setups on common classes of machine tools. • Gain competence in all safety procedures for all tasks within the scope of Machining

Skills—Level III. • Select and use cutting fluids.

Inspection and quality assurance skills:

• Develop and document inspection procedures for in-process inspection. • Inspect compound angles to required precision. • Develop inspection process plans. • Use visual comparator for inspection tasks. • Use gage blocks for shop calibration of precision tools.

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Other skills and competencies: • Write CNC programs requiring multiple tools, planes, canned cycles, and offsets. • Qualify tools for CNC use. • Participate effectively as a member of a team. • Maintain employment in the metalworking industry. • Articulate a personal career development plan within the metalworking industry. • Produce process plans which identify operations, sequence, tools, fixtures, speeds and

feeds for parts requiring several of the basic machining operations such as milling, drilling, turning, or grinding.

• Record work activities. • Write required work reports. • Succeed in interactive verbal and written communication. • Train others as assigned. • Perform supervisory duties.

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Machining Skills—Level III Duty and Skills Standards Table

The left-hand column is a list of activities performed on the job. The right-hand column is a list of the abilities, skills, knowledge, or other characteristics that are needed to perform the duties.

Occupational Duties

Knowledge, Skills, Abilities, and Other Characteristics

1. Job Planning and Management 1.1 Job Process Planning

1. Written and Oral Communications 1.1 Reading 1.2 Writing 1.3 Speaking 1.4 Listening

2. Job Execution 2.1 Bench Operations: Hand Lapping 2.2 Angle Contour Bandsawing 2.3 Turning Operations: Manual Contour Turning 2.4 Turning Operations: Steady Rest Turning & Boring 2.5 Turning Operations: Follower Rest Turning 2.6 Turning Operations: Difficult Materials 2.7 Milling: Mill Compound Angles 2.8 Milling: Manual Contour Milling 2.9 Horizontal Boring Mill: Line Boring 2.10a Grinding: Select, Inspect, Set up, & Balance Wheels 2.10b Grinding: Tapered Cylindrical Grinding 2.11 Grinding: Grind I.D. and O.D. Surfaces 2.12 Grinding: Grind Tapers on an Universal Grinder 2.13 Grinding: Contour Grinding 2.14 EDM: Operate a 4 Axis Wire EDM 2.15 CNC: Advanced Manual RS-274-D Programming 2.16 CNC: Use Manufacturing Modeling Software to Create RS-274-D Programs 2.17 CNC: Milling Centers 2.18 CNC: Turning Centers 2.19 CNC: Turning Centers with Secondary Milling

2. Mathematics 2.1 Geometry of Compound Angles, Profiles of a Line and Profile of a Surface

3. Quality Control and Inspection 3.1 Part Inspection 3.2 Process Control

3. Computer Aided Manufacturing Technology 3.1 Computer Aided Manufacturing Software

4. Process Adjustment and Control 4.1 Process Adjustment, Single Part Production 4.2 Participation in Process Improvement

4. Decision Making and Problem Solving 4.1 Applying Decision Rules 4.2 Basic Problem Solving

5. General Maintenance 5.1 General Housekeeping and Maintenance 5.2 Preventive Maintenance 5.3 Tooling Maintenance

5. Group Skills and Personal Qualities 5.1 Group Participation and Teamwork 5.2 Personal Qualities

6. Industrial Safety and Environmental Protection 6.1 Machine Operations and Material Handling 6.2 Hazardous Materials Handling and Disposal

6. Engineering Drawings and Sketches 6.1 Standard Orthographic Blueprints 6.2 GDT Orthographic Blueprints

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7. Career Management and Employment Relations 7.1 Career Planning 7.2 Job Applications and Interviewing 7.3 Teamwork and Interpersonal Relations 7.4 Organizational Structures and Work Relations 7.5 Employment Relations

7. Measurement 7.1 Basic Measuring Instruments 7.2 Precision Measuring Instruments 7.3 Surface Plate Instruments

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Machining Skills—Level III

Duty Area: 1. Job Planning and Management Duty Title: 1.1 Job Process Planning Duty: Write a detailed process plan that includes a quality plan for a part requiring milling, drilling, turning, or grinding. Produce an operation sheet detailing the process plan and required speeds and feeds. Provide sketches as needed. Performance Standard: Given a blueprint detailing a part requiring milling, drilling, turning, and grinding, verbal instructions, and appropriate references, formulate a set of strategies to manufacture the part and write a detailed process plan including a quality plan for that part. Provide sketches as needed. Make a presentation explaining each of the process plan steps to be taken, identify all major components and functions of the machine tools, and all major hand tools, measuring tools, tools and fixtures, work materials and provide the rationale for the speeds and feeds selected. Other Evaluation Criteria: 1. Legibility. 2. Clarity of the writing. 3. Appropriate speeds and feeds. Accuracy Level: N/A. Assessment Equipment and Material: Workstation: Standard workbench. Material: A blueprint with an appropriate part, an inventory of available tools, necessary writing

materials. Tooling: N/A. Measuring Instruments: N/A. Reference: Machinery's Handbook.

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KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Job Process Planning Duty.

Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views X Writing X Orthographic Blueprints: GDT Multiple Datums X Speaking Isometric and Orthographic Sketching X Listening Measurements Mathematics Basic Measurements X Arithmetic Optical Comparator X Geometry of Simple Angles & Line Profiles Manual Coordinate Measuring Machine X Coordinate Axes, Cartesian & Polar Metalworking Theory X Trigonometry for CNC Toolpaths X Cutting Theory Statistics for Capability Studies X CNC Tooling Decision Making and Problem Solving X Metal Properties & Cutting X Applying Decision X Non-metal Properties & Cutting X Basic Problem Solving X CNC Machine Tools Group Skills and Personal Qualities X Cutting Fluids and Coolants for Specific Jobs Group Participation Electrode Design and Selection Personal Qualities Computers Typing Services of an Operating System

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Machining Skills—Level III Duty Area: 2. Job Execution Duty Title: 2.1 Bench Operations: Hand Lapping Duty: Hand lap small surfaces to finish. Performance Standard: Given a blueprint, access to a lapping plate, an appropriate ground part, lapping compound, and cleaning solutions, lap a surface to flatness and finish requirements. Accuracy Level: .0001 flatness over 4" square surface, 8 microinch surface finish. Assessment Equipment and Material: Workstation: Standard workbench with a lapping plate that can be fixed in place.

Material: A part ground to the lapping blueprint, material: 1215 CRS . Lapping compound and cleaning solution, with appropriate disposal for both..

Tooling: Wipes. Measuring Instruments: Optical flats, indicators, electronic gages, laboratory grade surface plate,

transfer gage. Reference: Machinery's Handbook.

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Comment

KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Bench Operations Duty of Hand Lapping.

Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Isometric and Orthographic Sketching Listening Measurements Mathematics X Basic Measurements X Arithmetic Optical Comparator Geometry of Compound Angles Manual Coordinate Measuring Machine X Geometry of Profiles of a Surface Metalworking Theory Coordinate Axes, Cartesian & Polar Cutting Theory Trigonometry for CNC Toolpaths CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving Non-metal Properties & Cutting X Applying Decision CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Electrode Design and Selection Group Participation Computers Personal Qualities Typing Services of an Operating System

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Machining Skills—Level III Duty Area: 2. Job Execution Duty Title: 2.1 Angle Contour Bandsawing Duty: Set up and perform contour sawing to a layout that requires the part to be sawed at angles with respect to the top and/or bottom. Choose and mount appropriate blades. Weld, break, and reweld blades as necessary. Performance Standard: Given a part with a finished layout and access to an appropriate bandsaw and blades, finish saw the part to the layout maintaining the required angular relationships of the finish with respect to the top and/or bottom. Accuracy Level: +/- 1/32 on all fractions, unless otherwise specified on the blueprint. Assessment Equipment and Material:

Workstation: Standard workbench and an appropriate bandsaw. Material: A part matching the bandsaw blueprint, material: 1215 CRS . Tooling: A scriber, layout ink, prick punch, ball peen hammer, angle plate, C-clamps, magnifying

glass. Measuring Instruments: Combination set, radius gages, 6" dividers, surface gage, or layout

height gage. Reference: Machinery's Handbook.

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KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Angle Contour Bandsawing Duty.

Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Isometric and Orthographic Sketching Listening Measurements Mathematics X Basic Measurements X Arithmetic Optical Comparator X Geometry of Compound Angles Manual Coordinate Measuring Machine Geometry of Profiles of a Surface Metalworking Theory Coordinate Axes, Cartesian & Polar Cutting Theory Trigonometry for CNC Toolpaths CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving X Non-metal Properties & Cutting X Applying Decision CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Electrode Design and Selection Group Participation Computers Personal Qualities Typing Services of an Operating System

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Machining Skills—Level III Duty Area: 2. Job Execution Duty Title: 2.3 Turning Operations: Manual Contour Turning Duty: Set up and perform contour turning using tapers and form tools as necessary. Performance Standard: Given raw material, blueprint, hand, precision, and cutting tools, as well as access to an appropriate turning machine and its accessories, produce a part matching the process plan and the blueprint specifications using appropriate trade techniques and speeds and feeds. The part specified should have at least two diameters composed of a taper and two tangent radii. Accuracy Level: +/- .015 on all fractions, +/-.005 on all decimals unless otherwise specified on the blueprint. Diameters to be concentric within .001 T.I.R. Assessment Equipment and Material:

Workstation: A standard workbench, a toolroom engine lathe, a three-jaw universal scroll chuck, and a four-jaw independent chuck. The lathe may have a quick-change gear box with the threads called for on the blueprint available from the gear box. A pedestal grinding machine to offhand grind form tools.

Material: A part matching the material requirements of the turning blueprint, material: 1215 CRS .

Tooling: Tool post, right- and left-hand turning tools capable of turning to a square shoulder, a drill chuck, centerdrill, external undercut tools, 45o chamfer tools, assorted tool blanks for form tools, live center, dead center fitted to the spindle taper, magnetic base for a dial indicator, files, wrenches as necessary.

Measuring Instruments: Required micrometers, combination set, dial indicator, 6" rule, a 6" vernier, dial, or electronic caliper, surface finish comparison plates, optical comparator, appropriate taper ring gages and Prussian blue, or taper micrometer, or sine bar and indicator.

Reference: Machinery's Handbook.

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KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the

performance of the Manual Contour Turning Operations Duty. Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Isometric and Orthographic Sketching Listening Measurements Mathematics X Basic Measurements X Arithmetic X Optical Comparator X Geometry of Compound Angles Manual Coordinate Measuring Machine Geometry of Profiles of a Surface Metalworking Theory Coordinate Axes, Cartesian & Polar X Cutting Theory Trigonometry for CNC Toolpaths CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving X Non-metal Properties & Cutting X Applying Decision CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Electrode Design and Selection Group Participation Computers Personal Qualities Typing Services of an Operating System

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Machining Skills—Level III Duty Area: 2. Job Execution Duty Title: 2.4 Turning Operations: Steady Rest Turning and Boring Duty: Set up and perform turning and boring operations requiring a steady rest. Performance Standard: Given raw material, blueprint, hand, precision, and cutting tools, as well as access to an appropriate turning machine and its accessories, produce a part matching the process plan and the blueprint specifications using appropriate trade techniques and speeds and feeds. The part specified will extend far enough from the spindle to require the support of a steady rest to facilitate boring on its ends. The part will have at least two bores within +/-.001, one UNC external thread, one UNF external thread, and will require the reversal of the part end for end. Accuracy Level: +/- .015 on all fractions, +/-.005 on all decimals unless otherwise specified on the blueprint. Diameters to be concentric within .001 T.I.R. Assessment Equipment and Material:

Workstation: A standard workbench, a toolroom engine lathe, a steady rest, a three-jaw universal scroll chuck, and a four-jaw independent chuck. The lathe may have a quick change gear box with the threads called for on the blueprint available from the gear box.

Material: A part matching the material requirements of the turning blueprint, material: 1215 CRS.

Tooling: Tool post, right- and left-hand turning tools capable of turning to a square shoulder, an external threading tool matched to the profile of the thread called out on the turning

blueprint, a drill chuck, centerdrill, external undercut tools, 45o chamfer tools, live center, dead center fitted to the spindle taper, magnetic base for a dial indicator, files, wrenches as necessary and cutting fluids.

Measuring Instruments: Required micrometers, combination set, thread pitch gages, center gage, pitch micrometer, thread ring and plug gages, dial indicator, 6" rule, a 6" vernier, dial, or electronic caliper, dial bore gages, surface finish comparison plates, and indicator.


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KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Steady Rest Turning & Boring Operations Duty.

Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Isometric and Orthographic Sketching Listening Measurements Mathematics X Basic Measurements X Arithmetic Optical Comparator Geometry of Compound Angles Manual Coordinate Measuring Machine Geometry of Profiles of a Surface Metalworking Theory Coordinate Axes, Cartesian & Polar X Cutting Theory Trigonometry for CNC Toolpaths CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving X Non-metal Properties & Cutting X Applying Decision CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Electrode Design and Selection Group Participation Computers Personal Qualities Typing Services of an Operating System

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Machining Skills—Level III Duty Area: 2. Job Execution Duty Title: 2.5 Turning Operations: Follower Rest Turning Duty: Set up and perform turning operations benefiting from the use of a follower rest. Performance Standard: Given raw material, blueprint, hand, precision, and cutting tools, as well as access to an appropriate turning machine and its accessories, produce a part matching the process plan and the blueprint specifications using appropriate trade techniques and speeds and feeds. The part specified will have at least three diameters within +/-.001, one of which will be an extended turn that will benefit from the use of a follower rest. Accuracy Level: +/- .015 on all fractions, +/-.005 on all decimals unless otherwise specified on the blueprint. Diameters to be concentric within .001 T.I.R. Assessment Equipment and Material:

Workstation: A standard workbench, a toolroom engine lathe, a three-jaw universal scroll chuck, and a four-jaw independent chuck.

Material: A part matching the material requirements of the turning blueprint, material: 1215 CRS.

Tooling: Tool post, a follower rest, a steady rest, right- and left-hand turning tools capable of turning to a square shoulder, a drill chuck, centerdrill, drills, external undercut tools, 45o chamfer tools, live center, dead center fitted to the spindle taper, magnetic base for a dial indicator, files, wrenches as necessary, and cutting fluids.

Measuring Instruments: Required micrometers, combination set, dial indicator, 6" rule, a 6" vernier, dial, or electronic caliper, and surface finish comparison plates.


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KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Follower Rest Turning Operations Duty.


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Machining Skills—Level III Duty Area: 2. Job Execution Duty Title: 2.6 Turning Operations: Difficult Materials Duty: Set up and perform turning refractory materials. Performance Standard: Given a 300 series stainless steel other than 303, blueprint, hand, precision, and cutting tools, as well as access to an appropriate turning machine and its accessories, produce a part matching the process plan and the blueprint specifications using appropriate trade techniques and speeds and feeds. The part specified should have at least two diameters within +/-.001, one UNC external thread, one UNF external thread. Accuracy Level: +/- .015 on all fractions, +/-.005 on all decimals unless otherwise specified on the blueprint. Diameters to be concentric within .001 T.I.R. Assessment Equipment and Material:

Workstation: A standard workbench, a toolroom engine lathe, a three-jaw universal scroll chuck, and a four-jaw independent chuck.

Material: 300 series stainless steel, except 303 Tooling: Tool post, right-and left-hand turning tools capable of turning to a square shoulder, an external threading tool matched to the profile of the thread called out on the turning

blueprint, a drill chuck, centerdrill, drills, external undercut tools, 45o chamfer tools, live center, magnetic base for a dial indicator, files, wrenches as necessary.

Measuring Instruments: Required micrometers, combination set, thread pitch gages, center gage, pitch micrometer, thread ring gages, dial indicator, 6" rule, a 6" vernier, dial, or electronic caliper, and surface finish comparison plates.


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KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Difficult Materials Turning Operations Duty.

Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Isometric and Orthographic Sketching Listening Measurements Mathematics X Basic Measurements X Arithmetic Optical Comparator Geometry of Compound Angles Manual Coordinate Measuring Machine Geometry of Profiles of a Surface Metalworking Theory Coordinate Axes, Cartesian & Polar X Cutting Theory Trigonometry for CNC Toolpaths CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving Non-metal Properties & Cutting X Applying Decision CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Electrode Design and Selection Group Participation Computers Personal Qualities Typing Services of an Operating System

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Machining Skills—Level III Duty Area: 2. Job Execution Duty Title: 2.7 Milling: Mill Compound Angles Duty: Set up and mill flat surfaces at compound angles with respect to each other. Performance Standard: Given a previously squared-up block, blueprint, hand, precision, and cutting tools, a compound sine plate, or angle table, and access to an appropriate milling machine, mill compound angles. Inspect the angles using a sine bare or sine plate. Accuracy Level: +/- .015 on all fractions, +/-.002 on all decimals unless otherwise specified on the blueprint. Angles to +/-15' Assessment Equipment and Material:

Workstation: A standard workbench, an appropriate milling machine. Material: A part matching the material requirements of the compound angle blueprint, material:

1215 CRS. Tooling: Required cutters and adapters, milling vise, toolmaker's vise, sine plates, tilting tables,

clamps and studs, magnetic base for a dial indicator, files, wrenches as necessary. Measuring Instruments: Required micrometers, combination set, dial indicator, 6" rule, a 6" vernier, dial, or electronic caliper, bevel vernier protractor, tooling ball, precision pins, sine

bar, sine plate, gage blocks, surface plate, and surface finish comparison plates. Reference: Machinery's Handbook, calculator with trigonometry functions.

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KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Milling Compound Angles Duty.

Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Isometric and Orthographic Sketching Listening Measurements Mathematics X Basic Measurements X Arithmetic Optical Comparator X Geometry of Compound Angles Manual Coordinate Measuring Machine Geometry of Profiles of a Surface Metalworking Theory Coordinate Axes, Cartesian & Polar X Cutting Theory Trigonometry for CNC Toolpaths CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving X Non-metal Properties & Cutting X Applying Decision CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Electrode Design and Selection Group Participation Computers Personal Qualities Typing Services of an Operating System

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Machining Skills—Level III Duty Area: 2. Job Execution Duty Title: 2.8 Milling: Manual Contour Milling Duty: Set up and mill curved surfaces through linear moves of varying lengths using methods of approximation from tapers, radii, interpolation, and sectioned templates. Performance Standard: Given a previously squared-up block, blueprint, hand, precision, and cutting tools, a compound sine plate, or angle table, other profiling accessories and access to an appropriate milling machine, mill surfaces which are composed of non-linear profiles. Accuracy Level: +/- .015 on all fractions, +/-.002 on all decimals unless otherwise specified on the blueprint. Angles to +/-30'. Assessment Equipment and Material:

Workstation: A standard workbench, an appropriate milling machine. Material: A part matching the material requirements of the blueprint, material: 1215 CRS. Tooling: Required cutters and adapters, milling vise, toolmaker's vise, sine plates, tilting tables, template material, clamps and studs, magnetic base for a dial indicator, files, wrenches

as necessary. Measuring Instruments: Required micrometers, combination set, dial indicator, 6" rule, a 6" vernier, dial, or electronic caliper, bevel vernier protractor, tooling ball, precision pins

and surface finish comparison plates. Reference: Machinery's Handbook.

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KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Manual Contour Milling Duty.

Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Isometric and Orthographic Sketching Listening Measurements Mathematics X Basic Measurements X Arithmetic X Optical Comparator X Geometry of Compound Angles X Manual Coordinate Measuring Machine X Geometry of Profiles of a Surface Metalworking Theory Coordinate Axes, Cartesian & Polar X Cutting Theory Trigonometry for CNC Toolpaths CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving X Non-metal Properties & Cutting X Applying Decision CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Electrode Design and Selection Group Participation Computers Personal Qualities Typing Services of an Operating System

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Machining Skills—Level III Duty Area: 2. Job Execution Duty Title: 2.9 Horizontal Boring Mill: Line Boring Duty: Set up and bore a series of in-line concentric bores using line-boring techniques and the boring mill footstock. Performance Standard: Given a previously semi-finished part, blueprint, hand, precision, and cutting tools, and access to an appropriate boring mill, mill surfaces, diameters, and radii to match the blueprint. Accuracy Level: +/- .015 on all fractions, +/-.002 on all decimals unless otherwise specified on the blueprint. Angles to +/-15'. Assessment Equipment and Material:

Workstation: A standard workbench, an appropriate milling machine. Material: A part matching the material requirements of the blueprint, material: 1215 CRS. Tooling: Required cutters and adapters, boring bars and single point boring tools, milling vise, a

rotary table with power take off, clamps and studs, magnetic base for a dial indicator, files, wrenches as necessary.

Measuring Instruments: Required micrometers, combination set, dial indicator, 6" rule, a 6" vernier, dial, or electronic caliper, dial bore gages, and surface finish comparison plates.


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KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Horizontal Line Boring Duty.


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Machining Skills—Level III Duty Area: 2. Job Execution Duty Title: 2.10a Grinding: Select, Inspect, Set Up, and Balance Wheels Duty: Prepare grinding wheels for mounting in a cylindrical grinder or surface grinder. Mount the wheel and grind a 16 microinch finish on a surface. Dress as necessary. Performance Standard: Given a wheel and appropriate equipment prepare the wheel to go into service. Accuracy Level: N/A Assessment Equipment and Material: Workstation: A standard workbench and cylindrical grinder. Material: An appropriate grinding wheel. Tooling: Wheel balancer, counterweights, wheel arbor. Measuring Instruments:Dial test indicator, indicator mounting brackets Reference: Machinery's Handbook.

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KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Grinding Duty to Select, Inspect, Set Up & Balance Wheels.

Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Isometric and Orthographic Sketching Listening Measurements Mathematics X Basic Measurements X Arithmetic Optical Comparator Geometry of Compound Angles Manual Coordinate Measuring Machine Geometry of Profiles of a Surface Metalworking Theory Coordinate Axes, Cartesian & Polar X Cutting Theory Trigonometry for CNC Toolpaths CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving Non-metal Properties & Cutting X Applying Decision CNC Machine Tools X Basic Problem Solving Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Electrode Design and Selection Group Participation Computers Personal Qualities Typing Services of an Operating System

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Machining Skills—Level III Duty Area: 2. Job Execution Duty Title: 2.10b Grinding: Tapered Cylindrical Grinding Duty: Set up and grind tapers on a cylindrical grinder. Performance Standard: Given a part rough finished as a Morse taper, mount the part between centers and grind the required tapered diameter to finish. Dress the wheel as necessary. Accuracy Level: +/-.015 on fractions, +/-.005 on decimals, +/-.0002 on ground diameters. Assessment Equipment and Material: Workstation: A standard workbench and cylindrical grinder. Material: A part matching the material requirements of the cylindrical grinding blueprint,

material: 1215 CRS. Tooling: Centers for the headstock and tailstock, assorted grinding dogs, composition hammer,

assorted grinding wheels suitable for mounting to the spindle, files, magnetic base for indicators, and diamond dresser.

Measuring Instruments:Required micrometers, combination set, dial test indicator, 6" rule, gage blocks, surface condition comparison gages. Reference: Machinery's Handbook.

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KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Tapered Cylindrical Grinding Duty.


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Machining Skills—Level III Duty Area: 2. Job Execution Duty Title: 2.11 Grinding: Grind I.D. and O.D. Surfaces Duty: Set up and grind I.D. and O.D. surfaces on a universal grinding machine or OD/ID grinder. Performance Standard: Given a part rough finished on O.D.s and I.D.s, mount the part in an appropriate workholder and grind the diameters to the required finish. Grind the shoulders as necessary. Dress the wheel. Accuracy Level: +/-.015 on fractions, +/-.005 on decimals, +/-.0002 on ground diameters. Assessment Equipment and Material: Workstation: A standard workbench and I.D./O.D. grinder. Material: A part matching the material requirements of the blueprint, material: 1215 CRS. Tooling: Workholders, three- and four-jaw grinder's chucks, composition hammer, assorted

grinding wheels suitable for mounting to the spindle, files, magnetic base for indicators, and diamond dresser.

Measuring Instruments:Required micrometers, dial bore gages, dial test indicator, 6" rule, gage blocks, surface condition comparison gages.


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KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Grinding I.D. and O.D. Surfaces Duty.

Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Isometric and Orthographic Sketching Listening Measurements Mathematics XX Basic Measurements Arithmetic Optical Comparator Geometry of Compound Angles Manual Coordinate Measuring Machine Geometry of Profiles of a Surface Metalworking Theory Coordinate Axes, Cartesian & Polar X Cutting Theory Trigonometry for CNC Toolpaths CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving X Non-metal Properties & Cutting X Applying Decision CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Electrode Design and Selection Group Participation Computers Personal Qualities Typing Services of an Operating System

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Machining Skills—Level III Duty Area: 2. Job Execution Duty Title: 2.12 Grinding: Grind Tapers on a Universal Grinder Duty: Set up and grind tapers on a universal grinder. Performance Standard: Given a part rough finished on O.D.s and I.D.s, mount the part in an appropriate workholder and grind the tapered diameters to the required finish. Dress the wheel. Accuracy Level: +/-.015 on fractions, +/-.005 on decimals, +/-.0002 on ground diameters. Assessment Equipment and Material: Workstation: A standard workbench and universal grinder. Material: A part matching the material requirements of the blueprint, material: 1215 CRS. Tooling: Workholders, three- and four-jaw grinder's chucks, centers, drive dogs, indexers,

composition hammer, assorted grinding wheels suitable for mounting to the spindle, files, magnetic base for indicators, live center, tailstock, and diamond dresser.

Measuring Instruments:Required micrometers, dial bore gages, dial test indicator, 6" rule, gage blocks, surface condition comparison gages.


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KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Grinding of Tapers on a Universal Grinder Duty.


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Machining Skills—Level III Duty Area: 2. Job Execution Duty Title: 2.13 Grinding: Contour Grinding Duty: Set up and grind curved and irregular surfaces by using linear incremental moves, tapers, radii, interpolation, and approximation with the aid of a visual comparator and a radius dresser. Performance Standard: Given a rough finished part, mount the part in an appropriate workholder and grind the profile to the required finish. Dress the wheel as necessary. Accuracy Level: +/-.015 on fractions, +/-.005 on decimals, +/-.0002 on ground surfaces, +/-5'

on angles, 16 microinch finish. Assessment Equipment and Material: Workstation: A standard workbench and profile grinder. Material: A part matching the material requirements of the blueprint, material: A2 tool steel. Tooling: Workholders, grinder's vise, composition hammer, assorted grinding wheels suitable

for mounting to the spindle, files, magnetic base for indicators, radius dresser, and diamond dresser.

Measuring Instruments:Required micrometers, dial test indicator, 6" rule, gage blocks, visual comparator, surface condition comparison gages. Reference: Machinery's Handbook.

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KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Contour Grinding Duty.

Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Isometric and Orthographic Sketching Listening Measurements Mathematics X Basic Measurements X Arithmetic X Optical Comparator X Geometry of Compound Angles Manual Coordinate Measuring Machine X Geometry of Profiles of a Surface Metalworking Theory Coordinate Axes, Cartesian & Polar X Cutting Theory Trigonometry for CNC Toolpaths CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving Non-metal Properties & Cutting X Applying Decision CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Electrode Design and Selection Group Participation Computers Personal Qualities Typing Services of an Operating System

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Machining Skills—Level III Duty Area: 2. Job Execution Duty Title: 2.14 EDM: Operate a 4 Axis Wire EDM Duty: Operate a 4 axis wire electric discharge machine. Performance Standard: Given a print, process plan, an appropriate selection of wire electrodes, workholding devices, EDM fluids, and 4 axis wire EDM machine, perform the EDM operation called out on the process plan. Accuracy Level: Match the requirements of the blueprint. Assessment Equipment and Material: Workstation: A 4 axis wire EDM and a workbench. Material: A part matching the material requirements of the blueprint, material: 1018 HRS Tooling: An appropriate workholding device, screws, studs, nuts, washers, and clamps sufficient to secure the part to the table. Assorted parallels, files, magnetic base for indicators, and assorted hand tools. Measuring Instruments:Required micrometers, combination set, dial indicator, 6" rule, a 6" vernier, dial, or electronic caliper, adjustable parallels, edge finder, appropriate tools for determining squareness, and surface finish comparison standards. Reference: Machinery's Handbook.

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KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Operation of a 4 Axis Wire EDM Duty.

Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Isometric and Orthographic Sketching Listening Measurements Mathematics X Basic Measurements X Arithmetic X Optical Comparator X Geometry of Compound Angles X Manual Coordinate Measuring Machine X Geometry of Profiles of a Surface Metalworking Theory X Coordinate Axes, Cartesian & Polar X Cutting Theory X Trigonometry for CNC Toolpaths CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving X Non-metal Properties & Cutting X Applying Decision X CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities X Electrode Design and Selection Group Participation Computers Personal Qualities Typing Services of an Operating System

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Machining Skills—Level III Duty Area: 2. Job Execution Duty Title: 2.15 CNC: Advanced Manual RS-274-D Programming Duty: Using a computer and editor write sophisticated RS-274-D programs. Sophisticated programs will contain various combinations of change of plane, canned cycles, will employ multiple tools, cutter offsets, linear, circular and helical interpolation as well as requiring the matching of surfaces along lines and points of tangency in 3 axes. Store the results on computer media. Performance Standard: Given a blueprint and a process plan, write a program to drive a collection of tooling through the toolpaths needed to produce the part shown on the blueprint. The program will require change of tools, change of planes, use of "canned cycles", and tool offsets. Use a computer to write and store the program. Accuracy Level: Match the tolerance of the blueprint. Assessment Equipment and Material: Workstation: A personal computer, a software editor, and a printer. Material: A diskette and paper. Tooling: N/A. Measuring Instruments: N/A. Reference: Machinery's Handbook, EIA Standard RS-274-D, the manual for the machine tool the program is being written for.

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KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the CNC Advanced Manual RS-274-D Programming Duty.

Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views X Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Isometric and Orthographic Sketching Listening Measurements Mathematics X Basic Measurements X Arithmetic Optical Comparator X Geometry of Compound Angles Manual Coordinate Measuring Machine X Geometry of Profiles of a Surface Metalworking Theory X Coordinate Axes, Cartesian & Polar X Cutting Theory X Trigonometry for CNC Toolpaths X CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving X Non-metal Properties & Cutting X Applying Decision X CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Electrode Design and Selection Group Participation X Computers Personal Qualities X Typing X Services of an Operating System

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Machining Skills—Level III Duty Area: 2. Job Execution Duty Title: 2.16 CNC: Use Manufacturing Modeling Software to Create RS-274-D Programs Duty: Create RS-274-D programs using a manufacturing modeling software package. Performance Standard: Given a blueprint, use a graphics-based software package to develop a program to drive a collection of tooling through the toolpaths needed to produce the part shown on the blueprint. The program will require change of tools, change of planes, use of "canned cycles", and tool offsets. Accuracy Level: N/A. Assessment Equipment and Material: Workstation: A personal computer, a graphics-based tool path modeler/editor, a software editor, and

a printer. Material: A diskette and paper. Tooling: N/A. Measuring Instruments: N/A. Reference: Machinery's Handbook, EIA Standard RS-274-D, the manual for the machine tool the program is being written for.

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KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the Use of Manufacturing Modeling Software to Create RS-274-D Programs Duty.

Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views X Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Isometric and Orthographic Sketching Listening Measurements Mathematics X Basic Measurements X Arithmetic Optical Comparator X Geometry of Compound Angles Manual Coordinate Measuring Machine X Geometry of Profiles of a Surface Metalworking Theory X Coordinate Axes, Cartesian & Polar X Cutting Theory X Trigonometry for CNC Toolpaths X CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving X Non-metal Properties & Cutting X Applying Decision X CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Electrode Design and Selection Group Participation X Computers Personal Qualities X Typing X Services of an Operating System

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Machining Skills—Level III Duty Area: 2. Job Execution Duty Title: 2.17 CNC: Milling Centers Duty: Set up and operate a CNC milling center. Performance Standard: Set up the tooling and workpiece. Qualify the workpiece to the control. Prepare tools or load tools into tool magazine as required, qualify the tools to the control with respect to the work, match their identity to the program. Establish initial tool values or offsets. The part specified should have at least two steps with +/-.001 tolerances, one UNC tapped hole, an arc/tangent surface, and require an the use of at least one "canned cycle" available on the mill. Accuracy Level: Match the requirements of the blueprint. Assessment Equipment and Material: Workstation: A standard workbench, a CNC mill with continuous path capability on 2½ axes. Material: A part matching the material requirements of the blueprint, material: 1215 CRS. Tooling: A 6" milling vise or greater, screws, studs, nuts, washers, and clamps sufficient to

secure the vise or the part to the table. Assorted parallels, assorted cutters and cutter adapters fitted to the machine spindle, files, magnetic base for indicators, soft jaws for the vise and assorted cutters.

Measuring Instruments: Required micrometers, combination set, dial indicator, 6" rule, a 6" vernier, dial, or electronic caliper, adjustable parallels, edge finder, appropriate tools for determining squareness, and surface finish comparison plates. Reference: Machinery's Handbook.

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KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the CNC Milling Centers Duty.

Written and Oral Communication Engineering Drawings and Sketches X Reading X Orthographic Blueprints: Auxiliary Views Writing X Orthographic Blueprints: GDT Multiple Datums Speaking Isometric and Orthographic Sketching Listening Measurements Mathematics X Basic Measurements X Arithmetic Optical Comparator X Geometry of Compound Angles X Manual Coordinate Measuring Machine X Geometry of Profiles of a Surface Metalworking Theory X Coordinate Axes, Cartesian & Polar X Cutting Theory X Trigonometry for CNC Toolpaths X CNC Tooling Statistics for Capability Studies X Metal Properties & Cutting Decision Making and Problem Solving Non-metal Properties & Cutting X Applying Decision X CNC Machine Tools X Basic Problem Solving X Cutting Fluids and Coolants for Specific Jobs Group Skills and Personal Qualities Electrode Design and Selection Group Participation Computers Personal Qualities Typing Services of an Operating System

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Machining Skills—Level III Duty Area: 2. Job Execution Duty Title: 2.18 CNC: Turning Centers Duty: Set up and operate turning centers. Performance Standard: Set up the tooling and workpiece. Qualify the workpiece to the control. Prepare tools or load tools into tool magazine as required, qualify the tools to the control with respect to the work, match their identity to the program. Establish initial tool values or offsets. The part specified should have at least two diameters within +/-.001, one UNC external thread, one UNF external thread, an appropriate taper at each end of the part, and require an end-for-end swap. Accuracy Level: Match the requirements of the blueprint. Assessment Equipment and Material:

Workstation: A standard workbench, a CNC turning center of adequate capacity, a three-jaw universal scroll chuck, and a four-jaw independent chuck.

Material: A part matching the material requirements of the CNC turning blueprint, material: 1215 steel.

Tooling: Right- and left-hand turning tools capable of turning to a square shoulder, an external threading tool matched to the profile of the thread called out on the turning blueprint, a drill chuck, centerdrill, external undercut tools, live center, dead center fitted to the spindle taper, magnetic base for a dial indicator, files, wrenches as necessary.

Measuring Instruments: Required micrometers, combination set, thread pitch gages, center gage, pitch micrometer, thread ring gages, dial indicator, 6" rule, a 6" vernier, dial, or electronic caliper, surface finish comparison plates, appropriate taper ring gages and Prussian blue, or taper micrometer, or sine bar and indicator.


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KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the CNC Turning Centers Duty.


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Machining Skills—Level III Duty Area: 2. Job Execution Duty Title: 2.19 CNC: Turning Centers with Secondary Milling Duty: Set up and operate turning centers with secondary milling operations. Performance Standard: Set up the tooling and workpiece. Qualify the workpiece to the control. Prepare tools or load tools into tool magazine as required, qualify the tools to the control with respect to the work, match their identity to the program. Establish initial tool values or offsets. The part specified should have at least two diameters within +/-.001, one UNC external thread, one UNF external thread, an appropriate taper at each end of the part, and have a keyseat and crosshole requiring the secondary milling capability of the center. Accuracy Level: Match the requirements of the blueprint. Assessment Equipment and Material:

Workstation: A standard workbench, a CNC turning center of adequate capacity, a three-jaw universal scroll chuck, and a four-jaw independent chuck.

Material: A part matching the material requirements of the CNC turning blueprint, material: 1215 steel.

Tooling: Right- and left-hand turning tools capable of turning to a square shoulder, an external threading tool matched to the profile of the thread called out on the blueprint, a drill

chuck, centerdrill, drills, endmills, external undercut tools, 45o chamfer tools, live center, dead center fitted to the spindle taper, magnetic base for a dial indicator, files, wrenches as necessary.

Measuring Instruments: Required micrometers, combination set, thread pitch gages, center gage, pitch micrometer, thread ring gages, dial indicator, 6" rule, a 6" vernier, dial, or electronic caliper, surface finish comparison plates, appropriate taper ring gages and Prussian blue, or taper micrometer, or sine bar and indicator.


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KSAO: This table represents the kinds of knowledge, skills, abilities, or other characteristics that will be assessed in the performance of the CNC Turning Centers with Secondary Milling Duty.


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Machining Skills—Level III KSAO Area: 2. Mathematics KSAO: 2.1 Geometry of Compound Angles, Profiles of a Line, and Profile of a Surface KSAO Definition: Apply principles of Euclidean geometry to the production of compound angles, profiles of a line, and profiles of a surface. Performance Requirement: Given a compass, a set of pencils, a graduated straight edge, the necessary drawing paper, and a blueprint matching the requirements of duty, lay out successive sections matching the required profiles and angles arising from the profiles of a surface. Duty Standard Cross Reference Table: This table identifies some of the activities that require this KSAO. Duty Area Task Activity

Job execution Milling compound angles Machine angles and surfaces

Job execution Manual contour milling Machine angles and surfaces

Job execution Contour grinding Machine angles and surfaces

Job execution CNC milling center Machine angles and surfaces

Job execution CNC turning with secondary milling

Machine angles and surfaces

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KSAO Area: 3. Computer Aided Manufacturing Technology KSAO: 3.1 Computer Aided Manufacturing Software KSAO Definition: Apply computer aided manufacturing software to the development of information necessary to manufacture parts. Performance Requirement: Given prints, a computer, appropriate software, and necessary output devices, produce information required by a CAD/CAM environment. Duty Standard Cross Reference Table: This table identifies some of the activities that require this KSAO. Duty Area Task Activity

Job execution CNC: Use manufacturing modeling software to create RS-274-D programs.

Create information necessary to develop toolpath programs for CNC machine tools.

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APPENDIX A Cross-References to Machining Skills—Levels I & II

The Machining Skill Standards are in three levels. They are modular in approach in order to serve the needs of the many diverse operations in the metalworking profession. As a worker becomes a candidate for certification to higher skill levels certain basic skills must be mastered. The skills included in this appendix are the basic requirements for all levels and they will be a part of any skills evaluation. They are repeated in each standard so that each document can be a stand alone study guide. While this information has been provided, it is recommended that the candidate for each skill level review all three levels in order to plan the candidates future development and career path.

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KSAO Area: 1. Written and Oral Communication KSAO: 1.1 Reading KSAO Definition: Locates, understands, and interprets written technical and non-technical information in documents commonly found in the metalworking industry. These documents contain short and simple sentences, paragraphs and passages, phrases, quantitative information, specialized vocabulary, graphs, charts, schedules, simple instructions, and multi-step directions. All documents are written in standard English. Performance Requirement: Given a specific duty to perform and the necessary written information contained on relevant documents and information sheets, locate and read the necessary information and use this information to plan, execute, and evaluate the duty and answer questions about the content or meaning of the written information.

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Machining Skills—Level III Duty Standard Cross Reference Table: This table identifies some of the activities that require the Reading KSAO. Duty Area Task Activity

1. Job planning Prepare a process plan. Read blueprints. Read tool crib inventory. Read the handbook.

2. Job execution Benchwork Layout Operate machine tools.

Read blueprints. Read process plans. Read the handbook.

3. Quality and inspection Inspection Control

Read blueprints. Read inspection plan. Read sampling plan. Read charting instructions.

4. Process improvement Process adjustment Participation in improvement

Read blueprints. Read process plans. Read the handbook. Read team documents.

5. Maintenance Housekeeping Machine tool PM Tooling maintenance

Read checklists. Read manuals.

6. Safety and environment Operations and handling HazMat handling & storage Material storage

Read safety instructions.

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KSAO Area: 1. Written and Oral Communication KSAO: 1.2 Writing KSAO Definition: Communicates technical and non-technical information, messages, and ideas in writing using standard English commonly found in the metalworking industry. This writing includes the completion of forms, information sheets, reports, group meeting materials, and short memos. Performance Requirement: Given a specific duty to perform and the necessary instructions, forms, and materials to complete the writing requirements for that duty, complete the writing requirement.

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Duty Standard Cross Reference Table: This table identifies some of the activities that require the Writing KSAO. Duty Area Task Activity

1. Job planning Prepare a process plan. Write instructions on the process plan.


Write a record of job activities.


Write a record of inspection activities.


Write a record of adjustment and improvement activities.


Write a record of maintenance activities. Fill out history forms.


Write a record of the activities involving the handling and storage of standard and hazardous materials.

KSAO Area: 1. Written and Oral Communication KSAO: 1.3 Speaking KSAO Definition: Communicates technical and non-technical detailed information, messages, multi-step directions and ideas through oral communication using standard English and related cues and communication aids in conversations, discussions, and group meetings. Understands and responds to listener feedback and asks questions when needed in two-way and group conversations. Performance Requirement: Given a specific duty to perform and the necessary instructions, written documents, and communication aids and materials to complete the speaking requirements for that duty, complete the speaking requirement.

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Duty Standard Cross Reference Table: This table identifies some of the activities that require the Speaking KSAO. Duty Area Task Activity

1. Job planning Prepare a process plan. Verbally explain the process plan.


Explain job execution activities.


Explain inspection procedures. Explain control charts and their role in process control.


Propose process remedies. Explain the selected corrective actions. Explain fishbone charts. Explain root cause reasoning.


Explain the condition of machine tools and the maintenance actions taken.


Explain actions bearing on safe practice.

KSAO Area: 1. Written and Oral Communication KSAO: 1.4 Listening KSAO Definition: Listens for, receives, interprets, and recalls specific details, ideas, and multi-step instructions in verbal presentations, conversations, discussions, and group meetings conducted in standard English and supported by written materials and other communication cues and aids. Uses active listening skills in comprehending simple technical and non-technical verbal information. Performance Requirement: Given a specific duty to perform and the necessary written information contained on relevant documents and information sheets, listen for, comprehend, and incorporate oral information in the performance of the duty and answer questions about the content or meaning of the oral information.

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Duty Standard Cross Reference Table: This table identifies some of the activities that require the Listening KSAO. Duty Area Task Activity

1. Job planning Prepare a process plan. Listen to verbal instructions.


Listen to verbal instructions.









KSAO Area: 3. Decision Making and Problem Solving KSAO: 3.1 Applying Decision Rules KSAO Definition: Can follow a set of instructions laid out in a sequence. Can interpret and follow "if...then..." instructions. Performance Requirement: Given a specific duty to perform requiring a checklist of sequential instructions, carry out the duty making appropriate entries on the checklist.

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Duty Standard Cross Reference Table: This table identifies some of the activities that require the Applying Decision Rules KSAO. Duty Area Task Activity

1. Job planning Prepare a process plan. Sequence operations.


Follow the process plan, deviating according to decision rules where necessary.


Follow the quality plan, deviating according to decision rules where necessary.


Apply checklists and decision rules to process improvement.


Apply company procedures to housekeeping, PM, and TM.


Apply OSHA and EPA decision rules to the storage and handling of materials.

KSAO Area: 3. Decision Making and Problem Solving KSAO: 3.2 Basic Problem Solving KSAO Definition: Can establish new responses to unexpected problems of a simple nature. Can formulate the new responses into a sequence of instructions or a set of "if ... then ..." rules. Performance Requirement: Given a specific duty to perform and being furnished with a checklist of sequential instructions, carry out the duty according to the checklist responding appropriately to problems. Formulate those responses into "if ... then ..." rules. Duty Standard Cross Reference Table: This table identifies some of the activities that require the Basic Problem Solving KSAO. Duty Area Task Activity

1. Job planning Prepare a process plan. Sequence operations, providing alternatives according to availability of tools and equipment.


Follow a process plan, improvising new methods where unavailability of tooling makes the plan obsolete.

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KSAO Area: 4. Group Skills and Personal Qualities KSAO: 4.1 Group Skills KSAO Definition: Identify and demonstrate the appropriate social skills and related personal qualities in the performance of major duties requiring cooperative relations with supervisors, team leaders, and team members. Performance Requirement: Demonstrates understanding, friendliness, politeness, and empathy toward others including men and women, and with people from a variety of ethnic, social, and educational backgrounds. Works cooperatively with others and contributes to group efforts with ideas, suggestions, and positive feedback to group members. Demonstrates appropriate social and communication skills in resolving conflicts with supervisors, team leaders, and team members.

Duty Standard Cross Reference Table: This table identifies some of the activities that require the Social Skills KSAO. Duty Area Task Activity

1. Job planning Prepare a process plan. Work cooperatively in developing a process plan, taking input from supervisors and coworkers.


Work cooperatively by responding to the need to share common work spaces.


Work cooperatively by participating in cooperative SPC activities.


Work cooperatively in workgroups, developing process improvements.


Work cooperatively by returning common tools to their appropriate storage sites.

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KSAO Area: 4. Group Skills and Personal Qualities KSAO: 4.2 Personal Qualities KSAO Definition: Identify and demonstrate the appropriate personal qualities in performing major job duties and maintaining positive employment relations. Performance Requirement: Recognizes and demonstrates appropriate codes of conduct and values in the workplace and demonstrates honesty and integrity in exhibiting appropriate workplace behaviors. Assumes responsibility and demonstrates strong work ethic by exerting effort and perseverance in doing work tasks according to high standards. Maintains high standards of attendance, punctuality, and involvement in all major work tasks. Duty Standard Cross Reference Table: This table identifies some of the activities that require the Personal Qualities KSAO. Duty Area Task Activity


Demonstrates honesty and integrity in reporting the findings of inspection processes.


Demonstrates attendance and punctuality in attending meetings for the development of process improvement.


Demonstrates honesty and perseverance in the handling of materials according to EPA requirements.

KSAO Area: 3. Engineering Drawings and Sketches KSAO: 3.1 Isometric and Orthographic Sketching KSAO Definition: Sketch orthographic and isometric projections of parts or details to support non-verbal communication. Performance Requirement: Sketch a part or detail in support of a quality report. Duty Standard Cross Reference Table: This table identifies some of the activities that require this KSAO. Duty Area Task Activity

Job planning Write a process plan. Sketching

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KSAO Area: 3. Engineering Drawings and Sketches KSAO: 3.2 Interpreting Engineering Drawings: Geometric

Dimensioning and Tolerancing KSAO Definition: Read and interpret GDT drawings with multiple datums. Performance Requirement: Given a GDT print with multiple datums, inspect a part using GDT principles for compliance with the print. Duty Standard Cross Reference Table: This table identifies some of the activities that require this KSAO. Duty Area Task Activity

Job execution CNC programming Interpret drawing. Job planning Process planning Interpret drawing.

Quality Inspect using CMM. Interpret drawing.

KSAO Area: 3. Engineering Drawings and Sketches KSAO: 3.3 Interpreting Engineering Drawings: Auxiliary Views KSAO Definition: Read and interpret engineering drawings having multiple auxiliary views. Duty Performance: Given a print with multiple auxiliary views, inspect a part for compliance with the print. Duty Standard Cross Reference Table: This table identifies some of the activities which require this KSAO. Duty Area Task Activity

Job execution CNC programming Interpret drawing. Job planning Process planning Interpret drawing.

Quality Inspect using CMM. Interpret drawing.

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KSAO Area: 4. Measurement KSAO: 4.1 Manual Coordinate Measuring Machines KSAO Definition: Apply the capacities of CMMs to inspection. Performance Requirement: Inspect a part of appropriate complexity using a CMM. Establish datums, multiple planes, multiple surfaces, hole locations, and hole sides, and angles. Duty Standard Cross Reference Table: This table identifies some of the activities that require this KSAO. Duty Area Task Activity

Quality inspection Use CMM for inspection. Inspect a part.

Appendix A National Institute for Metalworking Skills Executive Committee

President Frank York Newman Machine Company Greensboro, NC President Elect Harold D. Walker Walker Machined Products Co. Collierville, TN 38027 Vice-President Larry Sippy SIPCO, Inc. Meadville, PA Secretary Dave Sansone Precision Metalforming Foundation Independence, OH Treasurer Bruce Braker Tooling and Manufacturing Association Park Ridge, IL Committee Member Scott Giesler Precision Machined Products Association Brecksville, OH Committee Member Matt Konieczny Oberg Manufacturing Company Freeport, PA Past-President: James B. McGregor Rose City Manufacturing Company Springfield, OH Prior Past-President Marvin Wortell Triton Industries Chicago, IL

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Appendix B NIMS Board of Directors Members and Staff Bill Bachman Robert Laudeman St Louis, MO US Department of Labor-BAT Baltimore, MD Jerry Benish CAMCRAFT, Inc Thomas Lewandowski Hanover Park, IL Ford Motor Company Canton, MI Nancy S. Berg Society of Manufacturing Engineers Terry Lyon Dearborn, MI Alcoa, Inc Alcoa, TN Jeffrey Edstrom Council of Great Lakes Governors James Meinert Chicago, IL Snider Mold, Inc. Mequon, WI Ron Engstrom Illinois State Board of Education Harry Moser Springfield, IL Charmilles Technology Lincolnshire, IL Ralph Hegman Hegman Machine Company Peter Rauterkus Maple Grove, MN Los Angeles Trade/Technical College Los Angeles, CA Dave Horn Assoc. for Manufacturing Technology Jerry Rodak McLean, VA The Timkin Company Canton, OH Paul Huber Industrial Precision Components Gregory Safco Bridgeport, CT. American Machine Tool Dist. Assoc. Rockville, MD Darryl Jerombeck Remmele Engineering, Inc. Bobby Veach New Brighton, MN RTS Wright Industries Nashville, TN

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Kenneth Kudek Richard Walker Focus Hope Nat’l Tooling and Machining Assoc. Detroit, MI Fort Washington, MD Dr. Robert Taylor Dennis Wulff Michigan Department of Education Dayton Rogers Corporation Lansing, MI Minneapolis, MN Project Staff Executive Director: Mr. Stephen C. Mandes National Institute for Metalworking Skills, Inc. Fairfax, VA Project Director: Mr. Robert W. Sherman, President Robert W. Sherman & Associates Vienna, VA Project Consultant Dr. Charles E. "Pete" Trott, Director Center for Governmental Studies Northern Illinois University DeKalb, IL

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