Modification History
New unit - Release 1
Unit Descriptor
This unit of competency covers the skills and knowledge needed to systematically examine aluminium extrusions for faults and to trace the reasons for the faults. This unit includes determining the most appropriate corrective action for the fault and, where appropriate, providing recommendations to extruder operators, die designers and die manufacturers.
Application of the Unit
This unit applies to die correctors working in an aluminium extrusion workplace who are required to investigate product fault reports, including determining the root cause of the fault, and recommending the most appropriate action. The unit applies to extrusions produced on solid and hollow dies and to faults that are both die and non-die related.
Band : A
Unit Weight : 6
Licensing/Regulatory Information
Not applicable.
Pre-Requisites
MEM09002B |
Interpret technical drawing |
MEM12023A |
Perform engineering measurements |
MEM12024A |
Perform computations |
MEM15002A |
Apply quality systems |
MEM15024A |
Apply quality procedures |
MEM16006A |
Organise and communicate information |
MEM18001C |
Use hand tools |
MEM18002B |
Use power tools/hand held operations |
Employability Skills Information
This unit contains employability skills.
Elements and Performance Criteria Pre-Content
Elements describe the essential outcomes of a unit of competency. |
Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold italicised text is used, further information is detailed in the required skills and knowledge section and the range statement. Assessment of performance is to be consistent with the evidence guide. |
Elements and Performance Criteria
1 |
Collect information on faulty extrusion |
1.1 |
Liaise with extruder operator on die service or fault correction requests |
1.2 |
Access and examine die following all relevant work health and safety (WHS) procedures |
||
1.3 |
Examine extruder records and identify any previous die corrections |
||
1.4 |
Consult with die designer on faults, where required |
||
1.5 |
Examine extruder maintenance records and liaise with maintenance department, where required |
2 |
Interpret die drawing and specifications |
2.1 |
Identify layout and pre-forming of die apertures |
2.2 |
Identify bearing and pocket design/specification |
||
2.3 |
Identify measurements and tolerances for bearings, die components and die support system |
||
2.4 |
Identify bolster and spacer specification for die |
||
2.6 |
Identify press specifications |
||
2.7 |
Identify speed estimate for die |
||
2.8 |
Identify ports and bridges for hollow dies |
3 |
Examine faulty extrusions |
3.1 |
Check extrusions for shape distortion |
3.2 |
Check extrusion measurements are to specification |
||
3.3 |
Inspect surface finish of extrusions for defects |
||
3.4 |
Identify whether faults apply from the start to the end of extrusion runouts |
||
3.5 |
Make a preliminary assessment as to whether faults are related to die or die support system or other factors |
4 |
Check for faults not related to die or die support system |
4.1 |
Examine die and billet heating and temperature records and confirm heating and temperature was to specification |
4.2 |
Confirm extruder was run at correct speed and other settings were to specification |
||
4.3 |
Examine billet history and determine if billet was recycled or faulty |
||
4.4 |
Confirm with maintenance department that extruder is free of mechanical, electrical, control or structural faults |
5 |
Identify die and die support related faults |
5.1 |
Safely access die and die support system |
5.2 |
Inspect die for overall wear, dishing, damage and other defects |
||
5.3 |
Inspect bearings for shortening, surface defects, loss of specified angle and clearances |
||
5.4 |
Determine if die can be corrected, scrapped or returned to manufacturer |
||
5.5 |
Inspect die support system and components for defects and die slide misalignment |
6 |
Record cause of fault and communicate as required |
6.1 |
Prepare recommendations for die correction and obtain any required approvals |
6.2 |
Prepare recommendations for any changes to process or temperature settings and distribute, as appropriate |
Required Skills and Knowledge
This section describes the skills and knowledge required for this unit. |
Required skills |
Required skills include:
|
Required knowledge |
Required knowledge includes:
|
Evidence Guide
The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria required skills and knowledge range statement and the Assessment Guidelines for the Training Package. |
|
Overview of assessment |
A person who demonstrates competency in this unit must be able to take a systematic approach to the identification of the cause of faults in aluminium extrusions and to determine the appropriate action to remedy the fault. |
Critical aspects for assessment and evidence required to demonstrate competency in this unit |
Assessors must be satisfied that the candidate can competently and consistently:
|
Context of and specific resources for assessment |
|
Method of assessment |
|
Guidance information for assessment |
Assessment processes and techniques must be culturally appropriate and appropriate to the language and literacy capacity of the candidate and the work being performed. |
Range Statement
The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included. |
|
Die support |
Die support is the specified toolstack dimensions that will support dies, according to the force the extruder can exert. |
Container |
The container is the part of the extruder that holds the billet and billet support components. |
Support tooling |
Support tooling is the name given to the various pieces of tooling (e.g. bolsters that provide stiffness to the die during extrusion). |
Die holder |
Die holders accommodate the diesets (feeder plate, die plate and backer). Die holders are the first components in toolstacks. |
Bolster |
Bolsters are deep discs of steel that provide stiffness in the toolstack to allow the die to remain flat and thus do its work properly. The term bolster includes any inserts designed to cut the cost of support tooling. |
Die slide |
The die slide is the part of the extruder that accommodates the dies and other tooling that makes up the toolstack. |
Toolstack |
The toolstack is the assembly of die, feeder plate and backer, holder and support tooling that fits into the die slide. |
Die |
The die is the part of the tooling that creates the extrusion shape as the metal is forced through it. |
Bearing |
The die contains bearings of various lengths. Bearings are lands that act as frictional controls on metal flow. The bearing is an outline of the extrusion shape cut through the die to the highest precision possible. |
Feeder plate |
The feeder plate precedes the die and provides an additional degree of flow control. It is also described as a control plate. It is bolted to the die and backer, forming the dieset. |
Faults |
Faults expected to be considered by a die corrector include faults in:
|
Backer |
The die must be given support against the force needed to make metal flow. The first item of support is the backer. Backer profiles are usually slightly larger than die apertures (precision cut) and are not high precision items. |
Platen plate |
The platen plate or pressure ring is set into the front wall of the press as a replaceable feature. Platen plates take up the forces applied to the toolstack and transmit them to the extruder structure. |
Primary and secondary bolsters |
|
Unit Sector(s)
Competency field |
Machine and process operations |
Unit sector |
Custom Content Section
Not applicable.