Work applies to determining repair requirements and grinding in an engine reconditioning process. Engine cylinder components to be machined may include those of light vehicles, heavy vehicles, agricultural and plant equipment, recreational vehicles and motorcycles.

ELEMENT

PERFORMANCE CRITERIA

1. Prepare to carry out grinding operations

1.1. Workplace instructions are used to determine job requirements, including method, process and equipment

1.2. Information is sourced, procedures and methods are analysed, and appropriate tooling options are selected for grinding engine components

1.3. Tools and measuring equipment are checked and prepared for operation

1.4. Safe operating procedures and workplace health and safety (WHS) and environmental requirements are observed throughout the work

1.5. Measuring and calibration requirements for grinding are determined

2. Grind engine components

2.1. Component is measured prior to grinding to determine depth of grind

2.2. Component is positioned in grinder and clamped

2.3. Grinding is carried out according to workplace procedures and without causing damage to components or system

2.4. Component is checked/measured with instruments to ensure compliance with specifications

2.5. Grinding operations are completed to specifications

3. Finalise grinding process

3.1. Components are thoroughly cleaned

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

3.3. Engine components are prepared for storage according to workplace requirements

3.4. Machined surfaces are treated with a protective coating to prevent rust if component is to be stored

3.5. Workplace documentation is processed according to workplace procedures

Required skills

technical skills to:

select correct grinding wheel for the application

identify irregularities in the grinding process

set machining parameters to achieve job requirements and maximise tool life

use appropriate and sufficient clamping or mounting of the work piece

use coolant and lubricant correctly

measure to specified tolerances and dimensions

communication skills to:

follow oral instructions

report deviations from specifications

interact with customers and team members

literacy skills to:

read and interpret routine job instructions, specifications, drawings and standard operating procedures

identify and analyse technical information

understand quality procedures

numeracy skills to use mathematical ideas and techniques to:

calculate time and assess tolerances

apply accurate measurements

calculate material requirements

establish quality checks

problem-solving skills to:

locate, interpret and apply workplace policies and procedures, including manufacturer and component supplier procedures

identify and avoid planning and scheduling problems

prevent time and material wastage

organise work and plan processes

self-management skills to:

select and use appropriate equipment, materials, processes and procedures

follow workplace documentation, such as codes of practice and operating procedures

technology skills to use communication devices and computerised equipment to:

search and gather supporting material

take, locate, download and view digital images

Required knowledge

WHS regulations and requirements, equipment, material and personal safety requirements, including:

personal protective equipment (PPE) for using grinding machines and chemical cleaning and lubricating agents

hazards associated with rotating grinding machines

manual-handling techniques relating to grinding crankshafts

types, characteristics and limitations of crankshaft grinding machines, including:

hand-held grinding machines for oil hole dressing

types and grades of grinding wheels, including grit grades

dismantling procedures of crankshafts, including:

numbering and removing counterweights

drive gears

oil seal sleeves and dowels

inspection procedures, including:

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 vee-blocks

measuring journals against specifications and identifying damaged journals

testing procedures of crankshaft, including:

crack testing coil shot and end shot

testing hardness of journals

procedures for preparing the crankshaft grinding wheel, including:

wheel preparation, including selecting wheel to suit radius and journal width of crankshaft

dressing procedures of wheel, including:

types of diamonds for front and radius dressing

procedure for dressing the wheel to suit crankshaft radius

procedure for dressing front of wheel

procedures for big-end grinding, including:

setting crankshaft rotation speed according to crankshaft material

setting crankshaft grinder wheelhead movement

measuring journal diameters and widths during grinding with constant measuring gauge

procedures for adjusting the crankshaft grinder to suit main bearing journal grinding, including:

removing the crankshaft from the grinder

setting chuck offsets for main bearings and adjusting counter weights to suit

fitting the crankshaft in the correct direction of rotation and ensuring that critical surfaces are not damaged by the chuck

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

setting crankshaft grinder wheelhead movement

measuring journal diameters and widths during grinding with constant measuring gauge

procedures for finishing journal grinding, including:

chamfering and dressing oil holes

linishing journals according to grade of belt and required finish

setting up and facing flange ends and seal areas

final grinding inspections of crankshaft, including journal surface finish, taper, ovality, barrelling, hour-glass, grinding chatter and journal burning

methods of correcting faults

procedures for removing crankshaft from grinder and checking crankshaft for straightness in vee-blocks using dial indicator

Australian standards relating to engine reconditioning

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

Critical aspects for assessment and evidence required to demonstrate competency in this unit

The evidence required to demonstrate competency in this unit must be relevant to workplace operations and satisfy all of the requirements of the performance criteria and required skills and knowledge.

A person who demonstrates competency in this unit must be able to:

observe safety procedures and requirements

select methods and techniques for grinding operations appropriate to the circumstances

complete preparatory activity in a systematic manner

grind a range of engine components according to workplace, manufacturer and component supplier requirements

complete work without damage to tools and equipment or injury to persons.

Context of, and specific resources for assessment

Competency is to be assessed in the workplace or a simulated workplace environment that accurately reflects performance in a real workplace setting. Performance is demonstrated consistently over a period of time and in a suitable range of contexts.

Assessment is to occur:

using standard workplace practices and procedures

following safety requirements

applying environmental constraints.

Assessment is to comply with relevant:

regulatory requirements

Australian standards

industry codes of practice.

The following resources must be made available for the assessment of this unit:

appropriate worksite

crankshafts and camshafts appropriate to the workplace, including in-line multi-cylinder engine blocks and vee-configuration multi-cylinder engine blocks

fixed and portable hand, air and power tools and equipment appropriate to grinding operations

specifications and work instructions.

Method of assessment

Assessment must satisfy the endorsed Assessment Guidelines of this Training Package.

Assessment methods must confirm consistency and accuracy of performance (over time and in a range of workplace relevant contexts) together with application of required skills and knowledge.

Assessment methods must be by direct observation of tasks and include questioning on required skills and knowledge to ensure its correct interpretation and application.

Assessment must confirm that competency is able not only to be satisfied under the particular circumstance, but is able to be transferred to other circumstances.

Competence in this unit may be assessed in conjunction with other units which together form part of a holistic work role.

Where applicable, reasonable adjustment must be made to work environments and training situations to accommodate ethnicity, age, gender, demographics and disability.

Assessment processes and techniques must be culturally sensitive and appropriate to the language and literacy capacity of the candidate and the work being performed.

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, 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.

Workplace instructions may include:

computer-generated instructions

verbal instructions

written instructions.

Information may include:

Australian standards

engineer’s design specifications and instructions

instructions issued by authorised workplace or external persons

workplace specifications and requirements

regulatory and legislative requirements relating to the automotive industry, including Australian Design Rules

safe work procedures relating to the operation of machinery associated with grinding engine components

verbal, written and graphical instructions, signage, work schedules, plans, specifications, work bulletins, memos, material safety data sheets (MSDS), diagrams or sketches.

Tools and measuring equipment may include:

arbors

clamps

dial bore gauges

dial indicators

inside and outside micrometers.

WHS requirements may include:

operational risk assessment and treatments associated with:

electrical safety

machinery movement and operation

manual and mechanical lifting and shifting

toxic substances

working in proximity to others and site visitors

PPE required by legislation, regulations, codes of practice and workplace policies and procedures.

Environmental requirements are to include:

clean-up management

dust and noise minimisation

waste management.

Measuring and calibration requirements may include:

determining journal diameters

determining sizes of grind.

Mechanical Miscellaneous

Sector

Technical - Manufacture

This unit contains employability skills.