Unit of Competency Mapping – Information for Teachers/Assessors – Information for Learners

AURTTM006 Mapping and Delivery Guide
Perform advanced machining and blueprinting of engine components

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency AURTTM006 - Perform advanced machining and blueprinting of engine components
Description
Employability Skills
Learning Outcomes and Application This unit describes the performance outcomes required to compare engine components to original manufacturer and component supplier specifications and match them in relation to weight, size and capacity. It involves preparing for the task, measuring and machining components to original manufacturer and component supplier specifications, and completing workplace processes and procedures.It applies to those working in the automotive service and repair industry. The engine components 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.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.

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 engine components that they have machined and blueprinted, 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 engine 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

two different multi-cylinder engines as specified in the performance evidence requiring machining and blueprinting

precision measuring equipment, including:

dial bore gauges

dial indicators

inside and outside metric and imperial micrometers

inside and outside spring calipers

fixed and portable hand, air and power tools

lifting equipment

material suitable for machining and blueprinting the engine components.
Prerequisites/co-requisites
Competency Field Mechanical Miscellaneous
Development and validation strategy and guide for assessors and learners Student Learning Resources Handouts
Activities 		Slides
PPT 		Assessment 1 Assessment 2 Assessment 3 Assessment 4
Elements of Competency Performance Criteria              
Element: Prepare to blueprint engine
  • Job requirements are determined from workplace instructions
  • Information is sourced, procedures and methods are analysed, and appropriate tools are selected for machining and blueprinting engines
  • Tools and measuring equipment are selected and checked for serviceability
  • Hazards associated with the work are identified and risks are managed
  • Cylinder block and cylinder head are prepared for blueprinting according to safety and environmental requirements
       
Element: Measure components
  • Measurements, clearances and tolerances are sourced and interpreted from manufacturer and component supplier literature
  • Components are measured and clearances and tolerances are calculated according to workplace procedures
       
Element: Machine components
  • Components are adjusted or machined to meet manufacturer and component supplier specifications according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures
  • Dummy assembly of engine is performed as required and clearances and tolerances are calculated according to workplace procedures
  • Further machining is carried out as required to achieve required clearances and tolerances
  • Engine is assembled according to job requirements and clearances, and tolerances are calculated again
  • Bright surfaces are treated with rust prevention solution and component is prepared for further process or storage according to workplace procedures
  • Blueprinting schedule documentation is completed according to workplace procedures
       
Element: Complete blueprinting and machining process
  • Final inspection is made to ensure finished work complies with workplace requirements
  • Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
  • Tools and equipment are checked and stored according to workplace procedures
  • Workplace documentation is processed according to workplace procedures
       
Element: Prepare to blueprint engine
  • Job requirements are determined from workplace instructions
  • Information is sourced, procedures and methods are analysed, and appropriate tools are selected for machining and blueprinting engines
  • Tools and measuring equipment are selected and checked for serviceability
  • Hazards associated with the work are identified and risks are managed
  • Cylinder block and cylinder head are prepared for blueprinting according to safety and environmental requirements
       
Element: Measure components
  • Measurements, clearances and tolerances are sourced and interpreted from manufacturer and component supplier literature
  • Components are measured and clearances and tolerances are calculated according to workplace procedures
       
Element: Machine components
  • Components are adjusted or machined to meet manufacturer and component supplier specifications according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures
  • Dummy assembly of engine is performed as required and clearances and tolerances are calculated according to workplace procedures
  • Further machining is carried out as required to achieve required clearances and tolerances
  • Engine is assembled according to job requirements and clearances, and tolerances are calculated again
  • Bright surfaces are treated with rust prevention solution and component is prepared for further process or storage according to workplace procedures
  • Blueprinting schedule documentation is completed according to workplace procedures
       
Element: Complete blueprinting and machining process
  • Final inspection is made to ensure finished work complies with workplace requirements
  • Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
  • Tools and equipment are checked and stored according to workplace procedures
  • Workplace documentation is processed according to workplace procedures
       


Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

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 blueprint engine

1.1 Job requirements are determined from workplace instructions

1.2 Information is sourced, procedures and methods are analysed, and appropriate tools are selected for machining and blueprinting engines

1.3 Tools and measuring equipment are selected and checked for serviceability

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

1.5 Cylinder block and cylinder head are prepared for blueprinting according to safety and environmental requirements

2. Measure components

2.1 Measurements, clearances and tolerances are sourced and interpreted from manufacturer and component supplier literature

2.2 Components are measured and clearances and tolerances are calculated according to workplace procedures

3. Machine components

3.1 Components are adjusted or machined to meet manufacturer and component supplier specifications according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures

3.2 Dummy assembly of engine is performed as required and clearances and tolerances are calculated according to workplace procedures

3.3 Further machining is carried out as required to achieve required clearances and tolerances

3.4 Engine is assembled according to job requirements and clearances, and tolerances are calculated again

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

3.6 Blueprinting schedule documentation is completed according to workplace procedures

4. Complete blueprinting and machining process

4.1 Final inspection is made to ensure finished work complies with workplace requirements

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

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

4.4 Workplace documentation is processed according to workplace procedures

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:

machine and blueprint two of the following different engine components:

engine with multiple overhead camshafts

V configuration engine with at least six cylinders

multi-cylinder diesel engine.

Individuals must be able to demonstrate knowledge of:

work health and safety (WHS) and occupational health and safety (OHS) requirements relating to performing advanced machining and blueprinting of engine components, including:

procedures for selecting and using personal protective equipment (PPE) for:

handling engine blocks and sub-assemblies

using chemical cleaning agents

operational risk assessment and treatments associated with:

electrical safety of machinery

machinery movement and operation

environmental requirements, including procedures for trapping, storing and disposing of cleaning and lubricating fluids released during process

procedures for preparing cylinder blocks and cylinder heads for blueprinting, including:

chemically cleaning engine components, including methods for avoiding damage or loss of components

chasing threads to remove debris with correct grade tap

hardness testing components

pressure testing cylinder heads

checking cylinder heads for bend on both sides

checking cylinder heads for minimum thickness

checking valve guides, valve stems, collets and valve springs for wear

testing engine block, including sonic testing and crack testing

dummy assembling engines, including reasons for dummy assembling engines

procedures for blueprinting cylinder blocks, including:

line boring main tunnels to produce datum

fitting bearings and checking crush

measuring main bearing tunnel with bearings fitted

grinding crankshaft to suit bearings and to achieve desired clearance and phasing consistency

sleeving lifter bores to centre line of camshaft and checking lifter to bore clearance and alignment to camshaft

fitting camshaft bearings and checking running clearances

squaring up deck to crankshaft tunnel to ensure crankshaft is parallel to block

fitting torque plate to bore and hone

honing cylinders to desired surface finish, matching individual pistons to respective bores

setting ring end gap

achieving consistent piston height for desired compression ratio and checking rotational clearance

procedures for blueprinting connecting rods, including:

shot peening connecting rods

preparing rod for re-sizing, including removing and locating dowels as required

selecting bolts

tensioning and re-sizing tunnel, maintaining centre-to-centre height

checking little end running clearance

removing bushes and checking parent bore of rod and bush fitment

pin fitting rod, maintaining centre-to-centre height and running clearance

checking alignment of rod

fitting up bearings, checking crush and running clearance

resizing connecting rods and fitting new bolts to ensure centre-to-centre length and alignment is correct

procedures to blueprint cylinder heads, including:

methods for achieving optimum airflow, including limitations of cylinder head modifications

machining for larger valves, including identifying machining shifts in castings

operating flow bench

porting for improved air flow and to balance combustion chambers

calculating capacity of individual combustion chambers and machining combustion chambers to achieve consistency

calculating compression ratio

selecting camshaft

setting valve heights

calculating installed height of valve springs and seat pressure

calculating valve spring open height and pressure

calculating valve spring solid height and coil bind clearance

calculating spring retainer to stem seal clearance

dialling camshaft

machining pistons to achieve desired compression ratio

setting rocker geometry, including length and sweep

requirements of Australian standards relevant 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.

Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assignment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)

Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

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 blueprint engine

1.1 Job requirements are determined from workplace instructions

1.2 Information is sourced, procedures and methods are analysed, and appropriate tools are selected for machining and blueprinting engines

1.3 Tools and measuring equipment are selected and checked for serviceability

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

1.5 Cylinder block and cylinder head are prepared for blueprinting according to safety and environmental requirements

2. Measure components

2.1 Measurements, clearances and tolerances are sourced and interpreted from manufacturer and component supplier literature

2.2 Components are measured and clearances and tolerances are calculated according to workplace procedures

3. Machine components

3.1 Components are adjusted or machined to meet manufacturer and component supplier specifications according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures

3.2 Dummy assembly of engine is performed as required and clearances and tolerances are calculated according to workplace procedures

3.3 Further machining is carried out as required to achieve required clearances and tolerances

3.4 Engine is assembled according to job requirements and clearances, and tolerances are calculated again

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

3.6 Blueprinting schedule documentation is completed according to workplace procedures

4. Complete blueprinting and machining process

4.1 Final inspection is made to ensure finished work complies with workplace requirements

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

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

4.4 Workplace documentation is processed according to workplace procedures

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.

Preparation must include:

ensuring surfaces are clean and oil and water passageways are clear using appropriate tools, such as a rifle brush.

Safety and environmental 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:

handling engine blocks and sub-assemblies

using chemical cleaning agents

operational risk assessment and treatments associated with:

electrical safety of machinery

machinery movement and operation

environmental requirements, including procedures for trapping, storing and disposing of cleaning and lubricating fluids released during process.

Blueprinting schedule documentation must include:

record of work performed, including tolerances and clearances achieved.

Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Job requirements are determined from workplace instructions 
Information is sourced, procedures and methods are analysed, and appropriate tools are selected for machining and blueprinting engines 
Tools and measuring equipment are selected and checked for serviceability 
Hazards associated with the work are identified and risks are managed 
Cylinder block and cylinder head are prepared for blueprinting according to safety and environmental requirements 
Measurements, clearances and tolerances are sourced and interpreted from manufacturer and component supplier literature 
Components are measured and clearances and tolerances are calculated according to workplace procedures 
Components are adjusted or machined to meet manufacturer and component supplier specifications according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures 
Dummy assembly of engine is performed as required and clearances and tolerances are calculated according to workplace procedures 
Further machining is carried out as required to achieve required clearances and tolerances 
Engine is assembled according to job requirements and clearances, and tolerances are calculated again 
Bright surfaces are treated with rust prevention solution and component is prepared for further process or storage according to workplace procedures 
Blueprinting schedule documentation is completed according to workplace procedures 
Final inspection is made to ensure finished work complies with workplace requirements 
Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected 
Tools and equipment are checked and stored according to workplace procedures 
Workplace documentation is processed according to workplace procedures 
Job requirements are determined from workplace instructions 
Information is sourced, procedures and methods are analysed, and appropriate tools are selected for machining and blueprinting engines 
Tools and measuring equipment are selected and checked for serviceability 
Hazards associated with the work are identified and risks are managed 
Cylinder block and cylinder head are prepared for blueprinting according to safety and environmental requirements 
Measurements, clearances and tolerances are sourced and interpreted from manufacturer and component supplier literature 
Components are measured and clearances and tolerances are calculated according to workplace procedures 
Components are adjusted or machined to meet manufacturer and component supplier specifications according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures 
Dummy assembly of engine is performed as required and clearances and tolerances are calculated according to workplace procedures 
Further machining is carried out as required to achieve required clearances and tolerances 
Engine is assembled according to job requirements and clearances, and tolerances are calculated again 
Bright surfaces are treated with rust prevention solution and component is prepared for further process or storage according to workplace procedures 
Blueprinting schedule documentation is completed according to workplace procedures 
Final inspection is made to ensure finished work complies with workplace requirements 
Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected 
Tools and equipment are checked and stored according to workplace procedures 
Workplace documentation is processed according to workplace procedures 

Forms

Assessment Cover Sheet

AURTTM006 - Perform advanced machining and blueprinting of engine components
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

Signature:

Date:

Assessment Record Sheet

AURTTM006 - Perform advanced machining and blueprinting of engine components

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

Date: