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

MEM04022A Mapping and Delivery Guide
Examine appropriateness of methoding for mould design

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency MEM04022A - Examine appropriateness of methoding for mould design
Description This unit of competency covers the skills and knowledge required to examine the methoding (gating, running and feeding of castings) for mould designs using basic metallurgical techniques and skills.
Employability Skills This unit contains employability skills.
Learning Outcomes and Application This unit of competency applies to a foundry tradesperson who has to examine the appropriateness of own or others methoding for a mould design using basic metallurgical skills and techniques supported by normal empirical trade skills. Work is performed under the general supervision of a metallurgist.Band: BUnit Weight: 4
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
Prerequisites/co-requisites Path 1MSATCM304A Interpret basic binary phase diagrams MEM04005C Produce moulds and cores by hand (jobbing) MEM09002B Interpret technical drawing MEM18001C Use hand tools
Competency Field Casting and moulding
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: Identify specification requirements for required casting
  • Obtain all relevant job requirements and design specifications in accordance with workplace procedures
  • Identify and interpret drawing requirements and specifications
       
Element: Evaluate proposed mould design for methoding requirements
  • Identify desired solidification process taking into account casting design, metal composition, mould design and specifications
  • Identify running, gating and feeding principles and techniques appropriate for the particular casting
  • Examine suitability of methoding if already selected including gating and the number, placement and sizing of feeders/risers
  • Where required, enter data to facilitate the generation of a computer simulation of methoding and casting process for later comparison to actual casting
       
Element: Report results
  • Determine reporting requirements
  • Prepare reports in accordance with standard operating requirements
  • Circulate and file report to procedures
  • Communicate suggestions for improvements directly to other team members where appropriate
       


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.

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

Evidence should be provided from the evaluation of a number of moulds. Evidence must be provided of manual calculations and compared to computer program results.

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

Assessors should ensure that candidates can competently and consistently:

calculate manually and by use of computer programs runner and feeding systems for casting designs within defined design parameters

examine mould designs for suitability against job specifications

understand the interplay between moulds, cores, gating and feeding

examine the resulting casting for success of gating and feeding

compare casting results with computer simulated predictions.

Context of and specific resources for assessment

Assessment may occur on the job or in an appropriately simulated environment. Access is required to real or appropriately simulated situations, including work areas, materials and equipment, and to information on workplace practices and OHS practices.

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

Access must be provided to appropriate learning and/or assessment support when required. Where applicable, physical resources should include equipment modified for people with disabilities.

Method of assessment

Assessment must satisfy the endorsed assessment guidelines of the MEM05 Metal and Engineering 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 underpinning knowledge.

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

Assessment may be applied under project related conditions (real or simulated) and require evidence of process.

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

Assessment may be in conjunction with assessment of other units of competency where required.

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.

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.

Required skills

Required skills include:

applying scientific principles to foundry mould design

examining mould designs using basic metallurgical skills and techniques to suit specific applications

calculating mould runner and feeding systems

selecting appropriate techniques and associated software and hardware technologies to suit specific applications in foundry mould design

presenting methoding solution and any associated limitations to mould design referring to the original aim of the application and any relevant instructions from metallurgist

Required knowledge

Required knowledge includes:

ability to perform calculations related to methoding and feeding including:

measuring dimensions of runner systems

calculating cross-sectional areas of sprue, runners and ingates

volumes and dimensions of feeders

the effects on solidification of:

nucleation

growth mechanisms (crystal and interfacial)

dendrite coherency

constitutional undercooling

superheat - effects, control and minimisation of excess heat

eutectic and peritectic solidification

grain structure

the principles underpinning the effective operation of running, gating and feeding systems including:

runner and gating principles (ratios)

determining type and placement of sprue, runners and ingates

inclusion control (slag and erosion)

calculations and effect of metal flow (lamellar and turbulent), velocity and temperature

calculation of feeder size

principles used in the determination of the location of feeders (end and feed zones, neighbourhood effect and feeding distances) including effect on solidification

exothermic and insulating feeding aids (sleeves and topping)

feeding mechanisms (liquid, mass, interdendritic, burst and solid)

use of computer packages (runner and feeder calculations and mould simulations) including benefits and limitations

yield calculations

risk management strategies to minimise defect formation and the methods for minimising:

shrinkage

porosity

segregation

hot tearing

shear

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.

Codes of practice/standards

Where reference is made to industry codes of practice and/or Australian/international standards, it is expected that the latest version will be used

Size and number of feeder heads and gating

Calculation of the size of feeder heads and gating includes manual calculation and use of computer programs within defined design parameters

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
Obtain all relevant job requirements and design specifications in accordance with workplace procedures 
Identify and interpret drawing requirements and specifications 
Identify desired solidification process taking into account casting design, metal composition, mould design and specifications 
Identify running, gating and feeding principles and techniques appropriate for the particular casting 
Examine suitability of methoding if already selected including gating and the number, placement and sizing of feeders/risers 
Where required, enter data to facilitate the generation of a computer simulation of methoding and casting process for later comparison to actual casting 
Determine reporting requirements 
Prepare reports in accordance with standard operating requirements 
Circulate and file report to procedures 
Communicate suggestions for improvements directly to other team members where appropriate 

Forms

Assessment Cover Sheet

MEM04022A - Examine appropriateness of methoding for mould design
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

MEM04022A - Examine appropriateness of methoding for mould design

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: