GHQ Diploma in Mechanical Engineering

Technology ENG05002NQ17
ENG04033NU17 – ENG5216
Operate & maintain CNC machines

Assessment-2 35%

Course ENG5216 Operate & Maintain CNC Machines

Term/Year Term 2 202021
Program Diploma in Engineering Technology – Mechanical Maintenance
Assessor Zaidoon kasawneh Duration 3 hours
Student Full Name BLOCK MBDDPGME201

2087-2095-2103
Student EID Number CRN
Student ID Number Student Class (S-T-U)-2

Student Declaration
I certify that the work presented is my own. It does not contain any material that is subject to
copyright or that has been submitted previously for assessment (Unless specifically requested by
teacher).

Student Signature Date

Elements Assessed

E1 Describe the main features of CNC machines

PC 1.2 Identify the main features of CNC milling machines and compare with manually operated milling machines.
PC 1.3 Describe the coordinate system and operation of CNC lathes.
. Createthe
PC 1.4 Describe a simple program
coordinate systemand
and safely runofonCNC
operation a CNC machine.
milling This should include conducting pres
machines
E2 Write and apply basic CNC programs
PC 2.2 Create a simple CNC program is and simulate its operation.
PC 2.3 Show how a CAM system canE2. Understand
be used to generateand
CNCapply basic CNC
programs.
PC 2.4 Show how to set up a CNC machine correctly and safely for a given program. E.g. Set up a CNC lathe for
facing, turning or other operations such as grooving and boring.
PC 2.5 Create a simple program and safely run it on a CNC machine. This should include conducting prestart checks,
loading and unloading the machine.
E3 Operate and monitor a CNC machine
PC 3.1 Follow CNC job instructions.
PC 3.2 Undertake CNC equipment pre-start checks and check safety equipment for correct operation.
PC 3.3 Install, select and verify the CNC program in accordance with job instructions
PC 3.4 Operate the CNC machine safely within product specification.
PC 3.5 Identify and report machine malfunctions.
PC 3.6 Check production samples for compliance with specification and report deviations from specification.

Assessment Instructions
 GHQ Diploma in Mechanical Engineering
Technology ENG05002NQ17
ENG04033NU17 – ENG5216
Operate & maintain CNC machines

All health and safety rule and regulations must be followed.

Practical project must be completed during class hours inside the workshop.
Each student must interpret and complete the product specified on the job sheet/working drawing
attached.
All documents and products must be handed to the assessor as part of the assessment.
Range Level
90 - 100% Distinction: Your achievement is outstanding relative to the course requirements.
75 - 89% Merit: Your achievement is significantly above the course requirements.
60 - 74% Competent: Your achievement satisfactorily meets course requirements.
0 - 59% Not Yet Competent: Your achievement does not meet course requirements.

Assessment Result Total /50 %

Teache Feedback and C mmen

S den C mmen

Assessment Event Feedback Acknowledgement

DO NOT SIGN UNTIL YOU RECEIVE THE FEEDBACK
I acknowledge that I have received and
understood feedback from my teacher about S den Signa e
this assessment event.
Date
I confirm that I have provided feedback
about this assessment to this student. Teache Signa e

Date
 TASK 1
Study the CNC Milling Machine user manual and label the parts ( ½ mark each) PC 1.2
 TASK 2
Several steps must be completed before manufacturing a part. Complete following flowchart of CNC machine
operations ( ½ mark each) PC 1.3,1.4
 TASK 3
Se e CNC ac e g a g e . PC 1.4

E ab a d e e CNC ac e g a g e b abe g e e a d efe e ce points on the

drawing below.

Machine Zero Point, M

Reference Point, R
Work Piece Zero Point, W
Tool Holder Reference Point, N (T)
 TASK 4
You are requested to run CNC milling machine program to produce the required part. Follow instructions
below to complete your project PC 2.2, 2.4, 2.5, 3.1, 3.2, 3.3, 3.4, 3.5

1. Start the CNC milling machine software and begin to type program in text editor.
2. Run simulations and verify your output.
3. Manufacture the part by following manufacturer operation guidelines.

Description Specification
Billet Aluminum
Dimension 80mm x 80mm x 10mm
Tools 4mm slot cutter
Depth 4mm
Drawing See the reference 1

Simulation

Final product
Program Sheet [PC 2.2]
(Print the CNC program and Attach here)
Print screenshot of simulation and paste here [PC 2.2, 2.4, 2.5]

Paste Photo Here

Photograph of final Product [PC 3.1, 3.2, 3.4]

Paste Photo Here

 Report
Write a brief report on how you produced the Component [PC2.3]
In your report you should include any faults or malfunction of the machine [PC 3.5]
On completion of the machining process, inspect the quality, finish and dimensional accuracy of the component
you have produced write the comments in the table below. PC 3.6
 TASK 5
You are requested to run CNC milling machine program to produce the required part. Follow instructions
below to complete your project PC 2.2, 2.3, 2.4, 2.5, 3.1, 3.2, 3.3, 3.4, 3.5

1. Generate CNC Program for the given CAD drawing

2. Run simulations and verify your output.
3. Manufacture the part by following manufacturer operation guidelines.

Description Specification
Billet Aluminium
Dimension 80mm x 80mm x 10mm
Tools 4mm slot cutter
Depth 4mm
Drawing See the reference 2

Simulation

Final product
Program Sheet [PC 2.3]
(Print the CNC program and Attach here)
Print screenshot of simulation and paste here [PC 2.2, 2.4, 2.5]

Paste Photo Here

Photograph of final Product [PC 3.1, 3.2, 3.4]

Paste Photo Here

 Report
Write a brief report on how you generated CNC code and machine operation [PC2.3]
In your report you should include any faults or malfunction of the machine [PC 3.5]

Assessment Rubrics:
Description Marking Rubrics Marks
Awarded
Task 1,Identify the main parts of CNC Milling Machine /3.5
Task 2, Draw the flow chart listing the main steps in CNC milling /4.5
Task 4 : CNC programming, simulation and manufacturing
Reading and (5 marks) (0 Mark)
interpreting the Reading the drawing and Not able to read the drawing
typing the program correctly and unable to type the /5
diagram
program correctly
correctly and
writing the CNC
program
Start the Milling machine software (1 mark)
Load CNC program(1 mark)
Configure the tooling in the CNC milling Software(1 mark)
Simulate the CNC program(1.5 marks)
Start and Home the CNC Machine(1 mark)
CNC operation / 12.5
Prepare any tooling Hardware for the CNC Machine(1 mark)
Load the billet onto the machine table(1 mark)
Configure the workpiece offset file and tool length
offsets(1mark)
Manufacture the part(2 marks)
Result/Output (2 marks)
(3 marks) (0 mark)
Inspect the High Dimensional Accuracy Inaccurate with Poor Finish
quality, finish with Good Finish
and dimensional
accuracy based /3
on the
Specification
(drawing)
(2 marks)
health and safety Observes all HSE rules and regulations every time.
procedures /2
during CNC (0 mark)
operation Does not follow HSE rules, regulations or procedures.
Task 5 : CNC program generation, simulation and manufacturing

Reading and (5 marks) (0 Mark)

Reading the drawing and Not able to read the drawing
interpreting the
Generating CNC program and unable to Generate the
diagram /5
correctly program correctly
correctly and
generating the
CNC program

Start the Lathe machine software (1 mark) / 12.5

CNC operation Load CNC program(1 mark)
 Configure the tooling in the CNC Lathe Software(1 mark)

Simulate the CNC program(1.5 marks)

Start and Home the CNC Machine(1 mark)
Prepare any tooling Hardware for the CNC Machine(1 mark)

Load the billet onto the machine table(1 mark)

Configure the workpiece offset file and tool length
offsets(1mark)
Manufacture the part(2 marks)
Result/Output (2 marks)
(2 marks)
health and safety Observes all HSE rules and regulations every time.
procedures /2
during CNC (0 mark)
operation Does not follow HSE rules, regulations or procedures.
Total Marks /50
 1. PRE-Operation:
Description C NC
Task (e.g. Drawings, instructions, specifications etc.) are clearly understood. (E3 ,PC1)
Identify ON/OFF switch and emergency stop button and test if operational. (E2,PC5)
Load the work piece and correct process tool safely and efficiently before starting material
removal. (E2,PC5)
Ensure CNC guard is in place.(E2,PC5)
Demonstrate knowledge of emergency procedures.
Ensure correct speed for machining process is selected in the program. (E2,PC2)

Write appropriate CNC code to manufacture the product (E2,PC2&5)

Task (e.g. Drawings, instructions, specifications etc.) are clearly understood. (E3 ,PC1)
Identify ON/OFF switch and emergency stop button and test if operational. (E2,PC5)

2. Operation:
Description C NC
Correct start-up of the machine and load the machine process correctly. (E2,PC5)
(E3,PC2)
Install, select and verify the CNC program in accordance with job instructions (E3, PC3)
Operate the CNC machine safely within product specification. (E3,PC4)
Monitor the machine process for safe operation and report any deviations faults as
required. (E3,PC5)

3. POST-Operation:
Description C NC
Unload the work piece correctly from the machine. (E2,PC5)
Switch off milling machine before removing waste material or work piece from the
milling machine.
Clean down the machine and remove any work piece, tools or swarf used/made during
operation. (E3,PC2)
The machine is safely restored for the next operator and any faults have been recorded for
maintenance
 References
Ref1: CAD drawing

Ref2: CAD Drawing