This unit applies to the manufacture of patterns for all types of cast gears, conveyor screws, marine propellers etc., utilising the full range of timbers and composites, appropriate pattern making principles and techniques. Gear patterns may be segmented or any other method used to minimise timber shrinkage or warpage and to achieve the required strength. Conveyor and marine screws may be built up using predetermined thicknessed timber, either over a mandrel or a layout. Patterns may be set up on a joint board or plated for ease of moulding.

Where precision measurement is required, Unit MEM12003B (Perform precision mechanical measurement) should also be considered.

When assembly of plated patterns is required, Unit MEM04012B (Assemble plated patterns) should also be considered.

Band: A

Unit Weight: 4

Path 1

MEM04010B

Develop and manufacture wood patterns

MEM04018B

Perform general woodworking machine operations

MEM09002B

Interpret technical drawing

MEM12006C

Mark off/out (general engineering)

MEM12023A

Perform engineering measurements

MEM12024A

Perform computations

MEM18001C

Use hand tools

MEM18002B

Use power tools/hand held operations

MEM30012A

Apply mathematical techniques in a manufacturing engineering or related environment

ELEMENT

PERFORMANCE CRITERIA

1. Determine job requirements

1.1. Drawings, instructions and specifications are interpreted and understood.

1.2. Appropriate material is selected to specifications.

1.3. Moulding, cast techniques and foundry processes are applied in determining the type of pattern required.

2. Lay out pattern

2.1. Pattern parameters are calculated.

2.2. Pattern is laid out showing tapers, machining allowances, core prints and method of construction etc. to specification.

2.3. Jigs and fixtures are developed and manufactured to aid the manufacture of the pattern form as required.

3. Manufacture pattern

3.1. Materials are marked out and construction is developed to meet specifications.

3.2. Pattern or pattern component parts are produced to size and shape and checked for compliance with specifications using acceptable wood pattern making techniques, procedures and utilising appropriate hand and hand held power tools.

3.3. Pattern component parts are joined or fixed as required, according to specifications, using acceptable pattern making techniques and procedures.

3.4. Pattern is correctly marked, colour-coded and/or tagged in compliance with specifications or standard operating procedures.

Required skills

Look for evidence that confirms skills in:

determining job requirements from written instructions, standard operating procedures, sketches, drawings and other applicable reference documents

planning and sequencing operations

checking and clarifying task-related information

selecting appropriate materials to suit the moulding/casting techniques and foundry process

laying out the pattern/core boxes

constructing patterns/core boxes

joining and fixing component parts

checking patterns

calculating contraction rates/pitch/proportions/profiles

undertaking relevant engineering calculations

Required knowledge

Look for evidence that confirms knowledge of:

timber, epoxy resin and composite product knowledge including features, characteristics and applications

moulding and casting techniques for cast gears, conveyor screws and marine propellers

tooling required for casting/moulding

methoding techniques

the use and application of jigs and fixtures

methods of construction

techniques, tools and equipment to measure, mark out&produce gear, conveyor screw&propeller patterns

mathematical calculations and formulae required to manufacture patterns/core boxes - contraction, taper, pitch, profiles, clearances, machining allowances

identification coding and numbering

pattern checking techniques

mouldability i.e. surface finish, face taper, convex or concave perspectives, undercuts, etc.

use and application of personal protective equipment

safe work practices and procedures

hazards and control measures associated with developing and manufacturing gear, conveyor screw and propeller patterns

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 develop and manufacture gear, conveyor screw and propeller patterns. Competency in this unit cannot be claimed until all prerequisites have been satisfied.

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

Assessors must be satisfied that the candidate can competently and consistently perform all elements of the unit as specified by the criteria, including required knowledge, and be capable of applying the competency in new and different situations and contexts.

Context of and specific resources for assessment

This unit may be assessed on the job, off the job or a combination of both on and off the job. Where assessment occurs off the job, that is the candidate is not in productive work, then an appropriate simulation must be used where the range of conditions reflects realistic workplace situations. The competencies covered by this unit would be demonstrated by an individual working alone or as part of a team. The assessment environment should not disadvantage the candidate.

This unit could be assessed in conjunction with any other units addressing the safety, quality, communication, materials handling, recording and reporting associated with manufacturing gear, conveyor screw and propeller patterns or other units requiring the exercise of the skills and knowledge covered by this unit.

Method of assessment

Assessors should gather a range of evidence that is valid, sufficient, current and authentic. Evidence can be gathered through a variety of ways including direct observation, supervisor's reports, project work, samples and questioning. Questioning techniques should not require language, literacy and numeracy skills beyond those required in this unit of competency. The candidate must have access to all tools, equipment, materials and documentation required. The candidate must be permitted to refer to any relevant workplace procedures, product and manufacturing specifications, codes, standards, manuals and reference materials.

Guidance information for assessment

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.

Material

Hardwood, softwood, epoxy resins, composites

Pattern parameters

Pitch circles, pressure angles, tooth form, left and right hand flight helix, pitch axial dimensions, angles, tapers, clearances, contraction allowances appropriate to developing various types of gear, conveyor and propeller forms

Calculated

The determination of contraction rates, pitch, proportions, profiles as well as general engineering calculations

Unit sector

Casting and moulding

This unit contains employability skills.