By the end of this chapter, you will be able to: - Select the right joining and assembly methods and prepare sub-assemblies to meet work requirements. - Join, fit, and assemble metal parts correctly using the specified techniques. - Inspect your finished assembly accurately to ensure it matches the required specifications. - Set the machine table and headstock on a milling machine so they are perfectly perpendicular and true. - Face a work piece precisely to match the given specifications. - Mill a work piece correctly, following all work requirements. - Thread a work piece accurately according to the job’s needs. - Drill or bore a work piece safely and correctly as specified. - Check that your finished work piece meets the required tolerance limits.
Mastering these skills will help you produce high-quality metal assemblies that meet industry standards and set you up for success in the workshop.
Type: Individual
| Tools & Equipment | Materials |
|---|---|
| Spanners (13mm and 19mm) | Metal plates 200mm x 150mm x 6mm thick |
| Center punch | Metal angle section 50mm x 50mm x 6mm thick |
| Hammer | Hex bolts M12 x 50mm |
| Drill machine with 13mm drill bit | Hex nuts M12 |
| Measuring tape 300mm | Flat washers M12 |
| Try square | Cleaning cloth |
| S/N | Item | Quantity |
|---|---|---|
| 1 | Metal plates 200mm x 150mm x 6mm thick | 2 pcs per Candidate |
| 2 | Metal angle section 50mm x 50mm x 6mm thick | 2 pcs per Candidate |
| 3 | Hex bolts M12 x 50mm | 8 pcs per Candidate |
| 4 | Hex nuts M12 | 8 pcs per Candidate |
| 5 | Flat washers M12 | 16 pcs per Candidate |
| 6 | Spanners (13mm and 19mm) | 1 set per Candidate |
| 7 | Center punch | 1 pc per Candidate |
| 8 | Hammer | 1 pc per Candidate |
| 9 | Drill machine with 13mm drill bit | 1 pc per Candidate |
| 10 | Measuring tape 300mm | 1 pc per Candidate |
| 11 | Try square | 1 pc per Candidate |
| 12 | Safety boots | 1 pair per Candidate |
| 13 | Overall | 1 per Candidate |
| 14 | Safety gloves | 1 pair per Candidate |
| 15 | Cleaning cloth | 100g per Candidate |
| Items to be Evaluated | Marks Available | Marks Obtained | Comments |
|---|---|---|---|
| TASK 1: Preparation and Safety | |||
| Wore appropriate personal protective equipment (safety boots, overall, gloves) (Award 1 mark for each PPE worn correctly) | 3 | ||
| Assembled all required tools and materials at the workstation (Award 1 mark or zero) | 1 | ||
| Checked and interpreted the working drawing (Award 1 mark or zero) | 1 | ||
| Sub-Total | 5 | ||
| TASK 2: Marking and Drilling | |||
| Measured and marked bolt hole positions accurately on metal plates and angle sections (Award 1 mark each for plates and angles) | 2 | ||
| Used center punch to mark drilling points (Award 1 mark or zero) | 1 | ||
| Drilled bolt holes with 13mm drill bit cleanly and accurately (Award 2 marks or zero) | 2 | ||
| Deburred drilled holes and cleaned metal surfaces (Award 1 mark or zero) | 1 | ||
| Sub-Total | 6 | ||
| TASK 3: Assembly and Tightening | |||
| Aligned metal plates and angle sections correctly as per drawing (Award 2 marks or zero) | 2 | ||
| Inserted bolts with flat washers and secured nuts with washers on the other side (Award 2 marks or zero) | 2 | ||
| Tightened all bolts and nuts to a secure fit using appropriate spanners (Award 2 marks or zero) | 2 | ||
| Cleaned assembled parts and cleared workstation (Award 1 mark or zero) | 1 | ||
| Sub-Total | 7 | ||
| PRODUCT CHECKLIST | |||
| Assembled metal parts match the working drawing dimensions (200mm x 150mm plates, 50mm angles) within ±2mm (Award 3 marks or zero) | 3 | ||
| Bolt holes are accurately aligned and bolts/nuts are properly tightened without gaps (Award 3 marks or zero) | 3 | ||
| Assembly is square and free from distortion as checked with try square (Award 2 marks or zero) | 2 | ||
| Sub-Total | 8 | ||
| GRAND TOTAL | 26 | ||
Type: Individual
| Tools & Equipment | Materials |
|---|---|
| Welding machine (arc welding) | Mild steel flat bars 50mm x 6mm |
| Angle grinder with cutting and grinding discs | Mild steel square tubes 30mm x 30mm x 3mm |
| Clamps and vice grips | Welding electrodes E6013 |
| Measuring tape 3m | |
| Try square | |
| Chipping hammer and wire brush |
| S/N | Item | Quantity |
|---|---|---|
| 1 | Mild steel flat bars 50mm x 6mm | 4 pcs per Candidate |
| 2 | Mild steel square tubes 30mm x 30mm x 3mm | 2 pcs per Candidate |
| 3 | Welding electrodes E6013 | 10 pcs per Candidate |
| 4 | Welding machine (arc welding) | 1 set per Candidate |
| 5 | Angle grinder with cutting and grinding discs | 1 pc per Candidate |
| 6 | Clamps and vice grips | 2 pcs per Candidate |
| 7 | Measuring tape 3m | 1 pc per Candidate |
| 8 | Try square | 1 pc per Candidate |
| 9 | Chipping hammer and wire brush | 1 set per Candidate |
| 10 | Safety gloves | 1 pair per Candidate |
| 11 | Welding helmet | 1 pc per Candidate |
| 12 | Safety boots | 1 pair per Candidate |
| 13 | Overall/Overcoat | 1 pc per Candidate |
| Items to be Evaluated | Marks Available | Marks Obtained | Comments |
|---|---|---|---|
| TASK 1: Preparation and Safety | |||
| Wore appropriate personal protective equipment (helmet, gloves, boots, overall) (Award 1 mark for each PPE worn correctly) | 4 | ||
| Assembled and checked welding tools and equipment for serviceability (Award 2 marks for complete and proper tool setup) | 2 | ||
| Measured and marked metal parts according to dimensions (Award 1 mark for each correctly measured and marked part) | 3 | ||
| Cut metal parts to correct lengths and deburred edges using angle grinder (Award 3 marks for accurate cutting and proper edge finishing) | 3 | ||
| Sub-Total | 12 | ||
| TASK 2: Assembly and Welding | |||
| Clamped metal parts firmly in position ensuring right angles (Award 3 marks for proper clamping and alignment) | 3 | ||
| Tack welded all joints to hold assembly in place (Award 3 marks for complete tack welding at all joints) | 3 | ||
| Completed full welding of all joints with correct bead size and penetration (Award 2 marks per side for neat, continuous weld beads with good penetration) | 6 | ||
| Cleaned welds using chipping hammer and wire brush (Award 2 marks for thorough cleaning removing slag and spatter) | 2 | ||
| Sub-Total | 14 | ||
| TASK 3: Finishing and Quality Checks | |||
| Checked assembled frame for correct dimensions (600mm x 400mm) using measuring tape (Award 3 marks for dimension accuracy within ±3mm) | 3 | ||
| Checked frame for squareness using try square (Award 3 marks if frame is square within acceptable tolerance) | 3 | ||
| Checked weld joints for defects such as cracks, porosity, or undercut (Award 3 marks if no visible defects found) | 3 | ||
| Completed task within the allocated time (Award 1 mark if task finished on time) | 1 | ||
| Sub-Total | 10 | ||
| PRODUCT CHECKLIST | |||
| Final metal frame sub-assembly dimensions 600mm x 400mm within ±3mm tolerance (Award 4 marks for dimension accuracy) | 4 | ||
| Frame is square and all joints are at 90 degrees within tolerance (Award 4 marks for squareness and alignment) | 4 | ||
| Welded joints are continuous, neat, with good fusion and free from defects (Award 6 marks for weld quality and appearance) | 6 | ||
| Overall workmanship and finish of the assembled frame (Award 4 marks for overall neatness and professional finish) | 4 | ||
| Sub-Total | 18 | ||
| GRAND TOTAL | 54 | ||
At the start of this chapter we promised you would be able to:
Tick each one you can genuinely do.
So, are you there yet?
You're competent when you can confidently do 50% or more of what this chapter promised.
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