This unit applies to open die forging of complex shapes commonly forged in the forging and fabrication areas of industry including forged bosses, heavy rings and bushes.

Specialised methods of holding, and positioning and lifting complex forgings are covered.

Equipment may include forging plant, diesel and gas furnaces.

For basic use of power hammer, Unit MEM06002B (Perform hammer forging) should be selected.

Band: A

Unit Weight: 4

Path 1

MEM06002B

Perform hammer forging

ELEMENT

PERFORMANCE CRITERIA

1. Set up and operate forging machine

1.1. The forging machine is set up and operated in accordance with standard operating procedures and specifications.

1.2. Complex open die tooling is selected and used according to workplace procedures.

1.3. Safe operating procedures are followed.

2. Forge complex shapes and heavy parts

2.1. The material to be forged is safely and correctly positioned in the forming equipment in accordance with standard operating procedures.

2.2. Hot forgings are marked and measured as required.

2.3. Allowance is made for material shrinkage and oxidisation.

2.4. Hammer tools and fixtures attached to power hammer are used correctly.

2.5. Forging is checked to ensure conformance to tolerances and specifications.

2.6. Forgings are handled safely and correctly according to workplace procedures.

3. Heat complex forgings

3.1. Heating plant and equipment is selected appropriate to work undertaken.

3.2. Techniques used to heat heavy and complex forgings are applied correctly.

3.3. Post-forging heating is performed correctly and safely.

3.4. Hot forgings are handled safely and according to workplace procedures.

Required skills

Look for evidence that confirms skills in:

selecting and using measuring guides

calculating allowance for material shrinkage and oxidisation

setting up and operating forging machine

selecting forming tools and equipment

positioning material

handling materials

selecting and setting up heating equipment

performing heat treatment process(es) for forging

Required knowledge

Look for evidence that confirms knowledge of:

hammer tools and formers and their applications

hammer forging techniques

numerical operations and calculations/formulae for data analysis within the scope of this unit

tools, formers and techniques to produce a range of hammer forged articles

procedures for measuring forged articles

effects of material shrinkage and oxidisation on the dimensions of the forged article

methods of overcoming/allowing for the effects of shrinkage and oxidisation when hammer forging articles

hammer punching techniques

procedures for handling material to be hammer forged

heating equipment and applications

heat treatment processes for forging

heat treatment requirements for given materials

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 hammer forge complex shapes. 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 hammer forging complex shapes 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.

Forge

Forging on and against cold mandrels

Hammer punching and opening of large diameter holes

Unit sector

Forging

This unit contains employability skills.