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

MEM07044 Mapping and Delivery Guide
Test a new aluminium extrusion die

Version 1.0
Issue Date: June 2024


Qualification -
Unit of Competency MEM07044 - Test a new aluminium extrusion die
Description
Employability Skills
Learning Outcomes and Application This unit of competency defines the skills and knowledge required for die correctors working in an aluminium extrusion workplace who are required to undertake the initial testing of new extrusion solid and hollow dies. It includes liaison with die designers and makers on the performance of the new die and making corrections to the die to ensure optimal performance.No licensing, legislative or certification requirements apply to this unit at the time of publication.Band: AUnit Weight: 4
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
Prerequisites/co-requisites
Competency Field Machine and process operations
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: Determine job requirements
  • Follow standard operating procedures (SOPs)
       
Element: Comply with work health and safety (WHS) requirements at all times
       
Element: Use appropriate personal protective equipment (PPE) in accordance with SOPs
       
Element: Identify job requirements from specifications, drawings, job sheets or work instructions
       
Element: Interpret die drawing and die specifications relevant to die trial
  • Identify regulatory requirements and risk management requirements associated with extruder operation and die handling
       
Element: Identify layout and pre-forming of die apertures
       
Element: Identify bearing and pocket design/specification
       
Element: Identify measurements and tolerances for bearings, die components and die support system
       
Element: Identify bolster and spacer specification for die
       
Element: Identify press specifications
       
Element: Identify speed estimate for die
       
Element: Identify ports and bridges for hollow dies
       
Element: Liaise with die designer
  • Clarify die drawing and die specifications with die designer where design information is not clear
       
Element: Determine if die requires finishing off and clarify final design measurements, tolerances and speed specifications
       
Element: Obtain any special instructions from die designer for conduct of test extrusions
       
Element: Finish off die, if required
  • Finish lands and bearings to specified tolerances
       
Element: Finish ports, bridges and mandrels of hollow dies, if required
       
Element: Undertake any final polishing
       
Element: Confirm all measurements are to design specification after finishing off
       
Element: Analyse trial extrusions
  • Check extruder and surrounds for compliance with operation safety requirements
       
Element: Operate or supervise operation of extrusion press to produce trial extrusions
       
Element: Check hot extrusions for shape distortion
       
Element: Check thickness of extrusions are to specification
       
Element: Check surface finish of extrusions
       
Element: Identify whether faults apply from the start to the end of the run-out of the extrusions
       
Element: Conduct additional trial extrusions to confirm extrusion faults occur consistently
       
Element: Record extruder settings for each trial extrusion
       
Element: Identify appropriate remedy for out-of-specification results
  • Examine faulty extrusions and determine if fault relates to die design, incorrect process or temperature settings, or faulty die support system
       
Element: Determine fault is die related and able to be eliminated through correction of die
       
Element: Determine if fault can be corrected through adjustments to die supports
       
Element: Determine if fault can be eliminated through adjusted process control or billet heating
       
Element: Recommend either return of die for re-design or manufacture of a new die where faults are unable to be corrected
       
Element: Re-test die after correction
  • Conduct trial extrusions after correction of die, die support adjustment or process or temperature adjustment
       
Element: Return die to die manufacturer if faulty extrusions persist
       
Element: Record adjustments to die on die design drawings ensuring correct feedback codes are used
       
Element: Record adjustments made to die support system, process and temperature settings
       

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.
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
Follow standard operating procedures (SOPs) 
 
 
 
Identify regulatory requirements and risk management requirements associated with extruder operation and die handling 
 
 
 
 
 
 
 
Clarify die drawing and die specifications with die designer where design information is not clear 
 
 
Finish lands and bearings to specified tolerances 
 
 
 
Check extruder and surrounds for compliance with operation safety requirements 
 
 
 
 
 
 
 
Examine faulty extrusions and determine if fault relates to die design, incorrect process or temperature settings, or faulty die support system 
 
 
 
 
Conduct trial extrusions after correction of die, die support adjustment or process or temperature adjustment 
 
 
 

Forms

Assessment Cover Sheet

MEM07044 - Test a new aluminium extrusion die
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

MEM07044 - Test a new aluminium extrusion die

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: