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Evidence Guide: MEM07042 - Undertake corrections and basic maintenance to aluminium extrusion dies and die support systems

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

The important thing to remember when gathering evidence is that the more evidence the better - that is, the more evidence you gather to demonstrate your skills, the more confident an assessor can be that you have learned the skills not just at one point in time, but are continuing to apply and develop those skills (as opposed to just learning for the test!). Furthermore, one piece of evidence that you collect will not usualy demonstrate all the required criteria for a unit of competency, whereas multiple overlapping pieces of evidence will usually do the trick!

From the Wiki University

 

MEM07042 - Undertake corrections and basic maintenance to aluminium extrusion dies and die support systems

What evidence can you provide to prove your understanding of each of the following citeria?

Correct solid dies

  1. Calculate intended change in extrusion flow or speed
  2. Determine bearing choke angles or length of bearing shortening as appropriate for required correction
  3. Speed up flow through appropriate shortening of bearing
  4. Slow down flow through appropriate choking of bearing
  5. Relieve clearances
  6. Supervise or run trial extrusions to test corrections
Calculate intended change in extrusion flow or speed

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine bearing choke angles or length of bearing shortening as appropriate for required correction

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Speed up flow through appropriate shortening of bearing

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Slow down flow through appropriate choking of bearing

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Relieve clearances

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Supervise or run trial extrusions to test corrections

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Correct hollow dies

  1. Assess if shortening or choking of mandrel bearings is required and select bearings to be corrected
  2. Determine choke angles and length of shortening as appropriate for required corrections
  3. Undercut mandrel to widen chambers
  4. Increase depth of chamber back into bridge
  5. Adjust mandrel stems
  6. Adjust weld bridges
  7. Speed up flow through appropriate shortening of bearing
  8. Slow down flow through appropriate choking of bearing
Assess if shortening or choking of mandrel bearings is required and select bearings to be corrected

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine choke angles and length of shortening as appropriate for required corrections

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Undercut mandrel to widen chambers

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Increase depth of chamber back into bridge

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Adjust mandrel stems

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Adjust weld bridges

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Speed up flow through appropriate shortening of bearing

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Slow down flow through appropriate choking of bearing

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Maintain die records

  1. Record details of all die corrections, including trial extrusions
  2. Recommend any simple die design changes that increase productivity and recovery
Record details of all die corrections, including trial extrusions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Recommend any simple die design changes that increase productivity and recovery

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine job requirements

  1. Follow standard operating procedures (SOPs)
Follow standard operating procedures (SOPs)

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Comply with work health and safety (WHS) requirements at all times

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Use appropriate personal protective equipment (PPE) in accordance with SOPs

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify job requirements from specifications, drawings, job sheets or work instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare for die correction

  1. Identify regulatory requirements and risk management procedures relevant to die access and handling, extruder operation and die correcting procedures
Identify regulatory requirements and risk management procedures relevant to die access and handling, extruder operation and die correcting procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify extrusion specifications, extruder operating procedures and other information relevant to die correction task

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Consult with die designer on intended correction, where required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Select appropriate hand tools, hand held power tools, or workshop machines to carry out die corrections

  1. Calculate intended change in extrusion flow or speed
Calculate intended change in extrusion flow or speed

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine bearing choke angles or length of bearing shortening as appropriate for required correction

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Speed up flow through appropriate shortening of bearing

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Slow down flow through appropriate choking of bearing

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Supervise or run trial extrusions to test corrections

  1. Assess if shortening or choking of mandrel bearings is required and select bearings to be corrected
Assess if shortening or choking of mandrel bearings is required and select bearings to be corrected

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine choke angles and length of shortening as appropriate for required corrections

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Undercut mandrel to widen chambers

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Increase depth of chamber back into bridge

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Undertake basic maintenance of dies

  1. Monitor case and assess when re-nitriding is required
Monitor case and assess when re-nitriding is required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare die for re-nitriding

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Repair fine bearing damage

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Maintain bearing angle and flatness during polishing and repairs

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor fittings and devices for lifting die and die support components and arrange replacement or repair as necessary

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Adjust die support system and components

  1. Ensure toolstack components are flat and square with die and specified toolstack dimensions that will support dies, according to the force the extruder can exert are used
Ensure toolstack components are flat and square with die and specified toolstack dimensions that will support dies, according to the force the extruder can exert are used

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check for and replace any coined bolsters

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check die slide alignment is within tolerance and re-align if necessary

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Report persistent die support related faults after adjustment and recommend redesign or stiffening as appropriate

  1. Record details of all die corrections, including trial extrusions
Record details of all die corrections, including trial extrusions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Recommend any simple die design changes that increase productivity and recovery

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Required Skills and Knowledge