^

 
 

Unit of competency details

AURTTM007 - Carry out crankshaft grinding (Release 1)

Summary

Usage recommendation:
Current
Mapping:
MappingNotesDate
Supersedes and is equivalent to AURTTM3007 - Carry out grinding operations 13/Apr/2016

Release Status:
Current
Releases:
ReleaseRelease date
1 1 (this release) 14/Apr/2016


Training packages that include this unit

Classifications

SchemeCodeClassification value
ASCED Module/Unit of Competency Field of Education Identifier 030503 Vehicle Mechanics  

Classification history

SchemeCodeClassification valueStart dateEnd date
ASCED Module/Unit of Competency Field of Education Identifier 030503 Vehicle Mechanics  09/Aug/2016 
The content being displayed has been produced by a third party, while all attempts have been made to make this content as accessible as possible it cannot be guaranteed. If you are encountering issues following the content on this page please consider downloading the content in its original form

Unit Of competency

Modification History

Release 

Comment 

Release 1 

New unit of competency.

Application

This unit describes the performance outcomes required to carry out grinding operations on engine crankshafts to specific under sizes. It involves preparing for the task, determining crankshaft damage and required repair action, preparing and using grinding machines to grind crankshafts to specifications, tolerances and workplace requirements, and completing workplace processes and documentation.

It applies to those working in the automotive service and repair industry. The crankshafts include those in vehicles from all sectors of the industry.

No licensing, legislative, regulatory or certification requirements apply to this unit at the time of publication.

Competency Field

Mechanical Miscellaneous

Unit Sector

Technical - Manufacture

Elements and Performance Criteria

Elements 

Elements describe the essential outcomes.

Performance Criteria 

Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold and italicised text is used, further information is detailed in the range of conditions section.

1. Prepare to grind crankshaft

1.1 Job requirements are determined from workplace instructions

1.2 Crankshaft is cleaned and inspected  and condition reported

1.3 Information is sourced, procedures and methods are analysed, and appropriate crankshaft grinding machine and equipment are selected for the crankshaft

1.4 Hazards associated with the work are identified and risks are managed

1.5 Tools and measuring equipment are selected and checked for serviceability

1.6 Crankshaft grinding wheel is prepared  according to machine manufacturer specifications and tolerances, and workplace procedures

1.7 Crankshaft is measured to determine under size and tolerances, including journal diameters and sizes of grind

1.8 Crankshaft is positioned in grinder in correct direction of rotation, and clamped according to manufacturer specifications and workplace procedures

2. Grind crankshaft big end bearing journals

2.1 Chuck offsets are set according to the stroke of crankshaft

2.2 Crankshaft grinder wheel head position is set according to machine manufacturer procedures

2.3 Constant measuring gauge and steady rest are positioned on big end journal taking into account position of oil hole

2.4 Crankshaft is ground at correct rotational speed for crankshaft material and diameter according to safety requirements , and following machinery safe operating procedures

2.5 Crankshaft is measured to ensure compliance with specifications and tolerances

2.6 Grinding operations are completed to required specifications and tolerances according to safety requirements, and following machinery safe operating procedures

3. Grind crankshaft main bearing journals

3.1 Crankshaft is removed from grinder

3.2 Chucks are centralised for main bearings and counterweights are adjusted

3.3 Crankshaft is refitted to grinder in correct direction of rotation, and is clamped according to manufacturer specifications and workplace procedures

3.4 Datum is set in relation to crankshaft rear flange and nose

3.5 Crankshaft grinder wheel head movement is set according to manufacturer procedures

3.6 Constant measuring gauge and steady rest are positioned on main bearing journal taking into account position of oil hole

3.7 Crankshaft is ground at correct rotational speed for crankshaft material and diameter according to safety requirements, and following machinery safe operating procedures

3.8 Crankshaft is inspected to ensure compliance with specifications and tolerances

3.9 Grinding operations are completed to required specifications and tolerances according to safety requirements, and following machinery safe operating procedures

4. Finish crankshaft grinding

4.1 Oil holes are chamfered and dressed

4.2 Journals are linished with correct grade of belt and in right direction of rotation and required finish

4.3 Flange ends and seal areas are faced

4.4 Crankshaft is examined and measured  according to manufacturer specifications and tolerances, and workplace procedures

4.5 Crankshaft is cleaned according to workplace procedures

4.6 Bright surfaces are treated with rust prevention solution and crankshaft is prepared for further process or storage according to workplace procedures

5. Complete work processes

5.1 Final inspection is made to ensure finished work complies with workplace requirements and crankshaft is presented ready for use or storage

5.2 Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected

5.3 Tools and equipment are checked and stored according to workplace procedures

5.4 Workplace documentation is processed according to workplace procedures

Foundation Skills

This section describes those language, literacy, numeracy and employment skills that are essential to performance and are not explicit in the performance criteria.

Skills 

Description 

Learning skills to:

  • locate appropriate sources of information efficiently.

Reading skills to:

  • interpret crankshaft specifications from workshop literature
  • interpret machinery safe operating procedures from operating manuals.

Writing skills to:

  • legibly and accurately fill out workplace documentation to record measurements.

Numeracy skills to:

  • interpret numerical information in manufacturer specifications, workshop literature, and machinery dials, gauges and computer readouts
  • use basic mathematical operations, including addition and subtraction, to:
  • convert metric dimensions to imperial, and imperial dimensions to metric
  • calculate tolerances and clearances.

Planning and organising skills to:

  • select best tooling option for the work and sequence procedure to reduce time and material wastage.

Technology skills to:

  • use metric and imperial precision measuring equipment.

Range of Conditions

This section specifies work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included. Bold italicised wording, if used in the performance criteria, is detailed below.

Cleaning and inspecting crankshaft  must include:

  • following procedures for chemically cleaning nitride and Tufftride crankshafts
  • inspecting crankshaft, including:
  • coil shot
  • end shot
  • hardness
  • alignment
  • bend
  • thread condition
  • key way condition
  • seal running surfaces condition
  • rear flange condition
  • nose gear condition.

Preparation  must include:

  • selecting wheel to suit radius and journal width
  • procedures for dressing wheel.

Safety requirements  must include:

  • work health and safety (WHS) and occupational health and safety (OHS) requirements, including procedures for:
  • selecting and using personal protective equipment (PPE) for using grinding machines and chemical cleaning and lubricating agents
  • identifying hazards associated with rotating grinding machines
  • manual handling techniques relating to grinding crankshafts.

Examining and measuring crankshaft  must include:

  • checking journals for:
  • acceptable surface finish
  • taper
  • ovality
  • barrelling
  • hourglass
  • grinding chatter and journal burning
  • checking crankshaft for straightness in V blocks using a dial indicator.

Unit Mapping Information

Equivalent to AURTTM3007 Carry out grinding operations

Links

Companion Volume implementation guides are found in VETNet - https://vetnet.gov.au/Pages/TrainingDocs.aspx?q=b4278d82-d487-4070-a8c4-78045ec695b1

 

Assessment requirements

Modification History

Release 

Comment 

Release 1 

New unit of competency.

Performance Evidence

Before competency can be determined, individuals must demonstrate they can perform the following according to the standards defined in this unit’s elements, performance criteria, range of conditions and foundation skills:

  • grind one crankshaft of an in-line petrol engine with at least four cylinders.

Knowledge Evidence

Individuals must be able to demonstrate knowledge of:

  • work health and safety (WHS) and occupational health and safety (OHS) requirements relating to grinding crankshafts, including procedures for:
  • selecting and using personal protective equipment (PPE) for using grinding machines and chemical cleaning and lubricating agents
  • identifying hazards associated with rotating grinding machines
  • manual handling techniques relating to grinding crankshafts
  • types, characteristics and limitations of crankshaft grinding machines, including:
  • hand-held machines for oil hole dressing
  • types and grades of grinding wheels, including grit grades
  • dismantling procedures for crankshafts, including:
  • numbering and removing counterweights
  • drive gears
  • oil seal sleeves and dowels
  • cleaning and inspection procedures, including:
  • chemically cleaning crankshafts, including methods of avoiding damage to nitride and Tufftride crankshafts
  • identifying crankshaft material
  • identifying heat treatment process, including nitriding, Tufftriding and induction hardening
  • identifying radius treatment, including deep fillet rolling, radius rolling and shot peening
  • checking alignment of crankshaft in V blocks
  • measuring journals against specifications and identifying damaged journals
  • testing procedures for crankshaft, including:
  • crack testing coil shot and end shot
  • testing hardness of journals
  • procedures for preparing crankshaft grinding wheel, including:
  • wheel preparation, including selecting wheel to suit radius and journal width of crankshaft
  • dressing procedures for wheel, including:
  • types of diamonds for front and radius dressing
  • procedures for dressing wheel to suit crankshaft radius
  • procedures for dressing front of wheel
  • procedures for big end grinding, including:
  • setting crankshaft rotation speed according to crankshaft material and big end diameter
  • setting crankshaft grinder wheel head position
  • setting chuck offsets for big end bearings and adjusting counterweights to suit
  • fitting crankshaft in correct direction of rotation and ensuring that critical surfaces are not damaged by the chuck
  • measuring journal diameters during grinding with constant measuring gauge
  • procedures for adjusting crankshaft grinder to suit main bearing journal grinding, including:
  • removing crankshaft from grinder
  • fitting crankshaft in correct direction of rotation
  • setting datum in relation to rear flange and nose for main bearing grinding
  • procedures for main bearing journal grinding, including:
  • setting crankshaft rotation speed according to crankshaft material and journal size
  • setting crankshaft grinder wheel head position
  • measuring journal diameters during grinding with constant measuring gauge
  • procedures for finishing journal grinding, including:
  • chamfering and dressing oil holes
  • linishing journals according to grade of belt, required finish, and rotational direction
  • setting up and facing flange ends and seal areas
  • final grinding inspections of crankshaft, including:
  • journal surface finish
  • taper, ovality, barrelling, and hourglass
  • grinding chatter
  • burning of radius and journals
  • methods of correcting faults
  • procedures for removing crankshaft from grinder and checking crankshaft for straightness in V blocks using dial indicator
  • requirements of Australian standards relating to engine reconditioning, including:
  • AS 4182 Automotive repairs – Code of practice for reconditioning reciprocating spark ignition engines
  • AS 4427 Automotive repairs – Code of practice for reconditioning reciprocating compression ignition engines
  • post-grinding operations, including rust protection of machined surfaces.

Assessment Conditions

Assessors must satisfy NVR/AQTF assessor requirements.

Competency is to be assessed in the workplace or a simulated environment that accurately reflects performance in a real workplace setting.

Assessment must include direct observation of tasks.

Where assessment of competency includes third-party evidence, individuals must provide evidence that links them to the crankshaft grinding that they have carried out, e.g. repair orders.

Assessors must verify performance evidence through questioning on skills and knowledge to ensure correct interpretation and application.

The following resources must be made available:

  • automotive repair workplace or simulated workplace
  • workplace instructions
  • manufacturer crankshaft specifications
  • AS 4182 Automotive repairs – Code of practice for reconditioning reciprocating spark ignition engines
  • AS 4427 Automotive repairs – Code of practice for reconditioning reciprocating compression ignition engines
  • crankshaft from an in-line petrol engine with at least four cylinders requiring grinding
  • engine crankshaft grinding machine
  • precision measuring equipment, including:
  • dial indicators
  • inside and outside metric and imperial micrometers.

Links

Companion Volume implementation guides are found in VETNet - https://vetnet.gov.au/Pages/TrainingDocs.aspx?q=b4278d82-d487-4070-a8c4-78045ec695b1

Companion Volume implementation guides are found in VETNet - https://vetnet.gov.au/Pages/TrainingDocs.aspx?q=b4278d82-d487-4070-a8c4-78045ec695b1