Tool And Die Maker - ITA BC
PROGRAM OUTLINETool and Die Maker
The latest version of this document is available in PDF format on the ITA websitewww.itabc.caTo order printed copies of Program Outlinesor learning resources (where available)for BC trades contact:Crown Publications, Queen’s PrinterWeb: www.crownpub.bc.caEmail: crownpub@gov.bc.caToll Free 1 800 663-6105Copyright 2011 Industry Training AuthorityThis publication may not be modified in any way without permission of the Industry Training Authority
TOOL AND DIE MAKERPROGRAM OUTLINEAPPROVEDOCTOBER 2010BASED ONNOA 2005Developed byIndustry Training AuthorityProvince of British ColumbiaTool and Die Maker08/13Industry Training Authority1
TABLE OF CONTENTSSection 1 INTRODUCTION. 1Foreword . 2How to Use this Document. 3Section 2 PROGRAM OVERVIEW . 5Occupational Analysis Chart . 8Training Topics and Suggested Time Allocation. 10Section 3 PROGRAM CONTENT . 12Level 1 Tool and Die Maker . 13Section 4 TRAINING PROVIDER STANDARDS . 39Facility Requirements. 40Tools and Equipment . 41Reference Materials . 43Instructor Requirements . 44Tool and Die Maker08/13Industry Training Authority2
IntroductionSection 1INTRODUCTIONTool and Die MakerTool and Die Maker08/13Industry Training Authority1
IntroductionForewordThe development of the Competencies for the Single Level Program for the BC Tool and Die MakerTrade was funded by the Industry Training Authority, and completed under the direction of the ResourceTraining Organization of BC. This Program’s new model is designed to be integrated with the BCMachinist Program and as such is built on the prerequisite of an apprentice Tool and Die Maker havingcompleted his Machinist apprenticeship and attained his Red Seal in this trade. Recognition is also givento Machinist apprentices who are able to serve their apprenticeship in a Tool and Die industrialworkplace.This document was developed in collaboration with a group of Subject Matter Experts (SMEs), all directlyconnected to the Tool and Die Making trade in BC, which met in June and November 2009 and alsoreviewed progressive drafts of this document.The development of the OAC and Competencies for BC Tool and Die Makers is based on three keydocuments: National Occupational Analysis for Tool and Die Maker, published by Human Resources andSkills Development Canada, 2005 BC Tool and Die Maker Apprenticeship Program Outline, published by the BC Ministry of Skills,Training and Labour – Apprenticeship Branch, 1995 BC Machinist Apprenticeship Program Outline, draft document funded by the BC IndustryTraining Authority, 2009The SMEs brought the perspectives of industry and education to the project and thanks are extended tothem for their dedication and participation in keeping the Tool and Die Maker trade technologically currentand aligned with the needs of industry.Tool and Die Maker Program Review SMEsNameAndrew ByersPositionTool and Die MakerSectorShipbuilding andMaintenanceJames CaiBC Institute ofTechnologyMachinist InstructorTraining ProviderUwe zum HingstZum HingstTechnologies Inc.Tool and Die MakerManufacturingRuss JonesAvcorp Industries Inc.Tooling ManagerAerospaceKarl ReichenbackBC Institute ofTechnologyTool and Die MakerInstructorTraining ProviderRichard TurnbullDepartment of NationalDefenceMachine ShopSupervisorShipbuilding andMaintenanceTool and Die Maker08/13OrganizationDepartment of NationalDefenceIndustry Training Authority2
IntroductionHow to Use this DocumentThis Program Outline has been developed for the use of individuals from several different audiences.The table below describes how each section can be used by each intended audience.SectionTraining am length andstructure, and allpathways sUnderstand the lengthand structure of theprogramUnderstand the lengthand structure of theprogram, and pathwayto completionUnderstandchallenger pathway toCertificate ofQualificationCommunicateprogram completionrequirements andassessment methodsUnderstand thevarious assessmentrequirements for theprogramUnderstand thevarious assessmentrequirements for theprogramUnderstand theassessmentrequirements theywould have to fulfill inorder to challenge theprogramOACCommunicate thecompetencies thatindustry has definedas representing thescope of theoccupationUnderstand thecompetencies that anapprentice is expectedto demonstrate inorder to achievecertificationView thecompetencies they willachieve as a result ofprogram completionUnderstand thecompetencies theymust demonstrate inorder to challenge theprogramTrainingTopics andSuggestedTimeAllocationShows proportionaterepresentation ofgeneral areas ofcompetency (GACs)at each program level,the suggestedproportion of timespent on each GAC,and percentage oftime spent on theoryversus practicalapplicationUnderstand the scopeof competenciescovered in thetechnical training, thesuggested proportionof time spent on eachGAC, and thepercentage of thattime spent on theoryversus practicalapplicationUnderstand the scopeof competenciescovered in thetechnical training, thesuggested proportionof time spent on eachGAC, and thepercentage of thattime spent on theoryversus practicalapplicationUnderstand therelative weightings ofvarious competenciesof the occupation onwhich assessment isbasedProgramContentDefines theobjectives, learningtasks, high levelcontent that must becovered for eachcompetency, as wellas definingobservable,measureableachievement criteriafor objectives with apractical componentIdentifies detailedprogram content andperformanceexpectations forcompetencies with apractical component;may be used as achecklist prior tosigning arecommendation forcertification (RFC) foran apprenticeProvides detailedinformation onprogram content andperformanceexpectations fordemonstratingcompetencyAllows individual tocheck programcontent areas againsttheir own knowledgeand performanceexpectations againsttheir own skill levelsTool and Die Maker08/13Employers/SponsorsIndustry Training Authority3
IntroductionSectionTraining ProvidersTrainingProviderStandardsDefines the facilityrequirements, toolsand equipment,reference materials (ifany) and instructorrequirements for theprogramTool and Die Maker08/13Employers/SponsorsIdentifies the tools andequipment anapprentice is expectedto have access to;which are supplied bythe training providerand which the studentis expected to ownApprenticesChallengersProvides informationon the training facility,tools and equipmentprovided by theschool and thestudent, referencematerials they may beexpected to acquire,and minimumqualification levels ofprogram instructorsIdentifies the toolsand equipment atradesperson isexpected to becompetent in using oroperating; which maybe used or provided ina practicalassessmentIndustry Training Authority4
Program OverviewSection 2PROGRAM OVERVIEWTool and Die MakerTool and Die Maker08/13Industry Training Authority5
Program OverviewProgram Credentialing ModelApprenticeship PathwayThis graphic provides an overview of the Tool and Die Maker apprenticeship pathway.C of Q Certificate of QualificationC of A Certificate of ApprenticeshipREDSEALC of QTool and DieMakerC of ATool and DieMakerRECOMMENDATION FOR CERTIFICATIONTool and Die Maker Level 1Technical Training: 300 hours (10 weeks*)Work‐Based Training: 3,300 hours totalInterprovincial Red Seal ExamAPPRENTICESHIP ‐ DIRECT ENTRYREDSEALC of QMachinist*Suggested duration based on 30‐hour weekCROSS‐PROGRAM CREDITSIndividuals who hold the credentials listed below are entitled to receive partial credit toward the completion requirements of this programREDSEALC of QMachinistTechnical Training: NoneWBT: Up to 1,650 hoursWork experienced must be accumulated through Tool and Die Makerspecific workTool and Die Maker08/13Industry Training Authority6
Program OverviewChallenge PathwayThis graphic provides an overview of the Tool and Die Maker challenge pathway.C of Q Certificate of QualificationREDSEALC of QTool and DieMakerCompletion RequirementsInterprovincial Red Seal ExamPrerequisitesApproved challenge application, including:Trade‐Related Work Experience: 12,375 hoursMachinist Certificate of Qualification withInterprovincial Red Seal EndorsementCREDIT FOR PRIOR LEARNINGIndividuals who hold the credentials listed below are considered to have met or partially met the prerequisites for challenging this programREDSEALC of QMachinistTool and Die Maker08/13Work Experience: up to 7,425 hoursIndustry Training Authority7
Program OverviewOccupational Analysis ChartTOOL AND DIE MAKEROccupational Description: “Tool and Die Maker” means a person who makes, repairs and tests dies, cutting tools, jigs, fixtures, moulds, gauges andspecial hand tools by laying out, setting-up, machining, fitting and finishing metal stock and castings.CUSE APPLIEDMATHEMATICSDUSE MEASURINGTOOLSC4 KSolve problems involvinggeometryC7 KSolve problems involvingtrigonometryM1M11M2M31D6 KInspect workpieces1FSELECT MATERIALSF5 KSelect materials forapplicationsM3GPLAN SEQUENCE OFOPERATIONF7 KDescribe materialstesting1M3M41G5 WDeburr workpieces1IUSE DRILLINGMACHINESI4 KPerform drilling processesfor tool and die making1KUSE LATHESK5 KDescribe the use ofadvanced cutting toolsM21NOTE: Competency numbering aligns with the BC Machinist 2009 OAC. Competency levels numbered “M#” here are pre-requisites under the Machinist program.Tool and Die MakerTool & Die Outline August 2013Industry Training Authority8
Program OverviewLUSE MILLINGMACHINESL5 KMill pockets and profilesfor tool and die making1MUSE SUPPORTMACHINESM3 WOperate and maintaingear cutting and electricaldischarge machinesM4NUSE GRINDERS ANDABRASIVESN3 WOperate and maintaingrindersM1QDESCRIBEPROTOTYPES1M3M4 KDescribe the use of wireelectrical dischargemachines in tool and diemaking1N5 KDescribe the operationand maintenance ofsurface grindersN4 WOperate and maintainsanders and polishers1M11N6 WGrind profiles for tool anddie making11Q1 KDescribe prototypingmaterials and processes1RBUILD JIGS ANDFIXTURESR1 KDescribe jigs and fixturesR2 WDesign jigs and fixtures1SBUILD DIESS1 KDescribe dies1S2 WDesign dies1TDESIGN AND MAINTAINMOULDSR3 WBuild jigs and fixturesT1 KDescribe mould building11S3 WBuild dies11S4 KDescribe the setup of dieand punch presses forsafe operation1T2 WDesign and maintaininjection moulds1NOTE: Competency numbering aligns with the BC Machinist 2009 OAC. Competency levels numbered “M#” here are pre-requisites under the Machinist program.Tool and Die MakerTool & Die Outline August 2013Industry Training Authority9
Program OverviewTraining Topics and Suggested Time AllocationTOOL AND DIE MAKER% of TimeUSE APPLIED MATHEMATICSC4C7Solve problems involving geometrySolve problems involving trigonometryLine DUSE MEASURING TOOLSD6Inspect workpiecesLine FSELECT MATERIALSF5F7Select materials for applicationsDescribe materials testingLine GPLAN SEQUENCE OF OPERATIONSG5Deburr workpiecesLine IUSE DRILLING MACHINESI4Perform drilling processes for tool and die makingLine KUSE LATHESK5Describe the use of advanced cutting toolsLine LUSE MILLING MACHINESL5Mill pockets and profiles for tool and die makingLine M5%M4USE SUPPORT MACHINESOperate and maintain gear cutting and electrical dischargemachinesDescribe the use of wire electrical discharge machines in tooland die makingLine NN3N4N5N6USE GRINDERS AND ABRASIVESOperate and maintain grindersOperate and maintain sanders and polishersDescribe the operation and maintenance of surface grindersGrind profiles for tool and die making5%Line QDESCRIBE PROTOTYPES2%Tool and Die Maker08/13Practical4%Line CM3Theory 4% 4%4% 3% 4%5%Industry Training Authority 10
Program Overview% of TimeDescribe prototyping materials and processesBUILD JIGS AND FIXTURESDescribe jigs and fixturesDesign jigs and fixturesBuild jigs and fixturesLine SS1S2S328%S4BUILD DIESDescribe diesDesign diesBuild diesDescribe the setup of die and punch presses for safeoperationLine TT1T2DESIGN AND MAINTAIN MOULDSDescribe mould buildingDesign and maintain injection moulds11%Tool and Die Maker08/13Industry Training AuthorityPractical Q1Line RR1R2R3Total Percentage for Tool and Die Maker – Level 1Theory21% 100%11
Program ContentSection 3PROGRAM CONTENTTool and Die MakerTool and Die Maker08/13Industry Training Authority12
Program ContentLevel 1Level 1Tool and Die MakerTool and Die Maker08/13Industry Training Authority13
Program ContentLevel 1LINE (GAC):CUSE APPLIED MATHEMATICSCompetency:C4Solve problems involving geometryObjectivesTo be competent in this area, the individual must be able to solve complex geometric problems related totool and die making.LEARNING TASKSCONTENT1. Solve complex geometric problems related todesigning and making tools and dies 2. Convert orthographic (2D) to isometric (3D)drawingsTool and Die Maker08/13Complex geometry applied to making: Die making Mould making Jig and fixture making Geometric dimensions and tolerances Picture a part in “negative” or mirror image Points in space (for parts that must fittogether) Given an orthographic drawing, convert toan isometric drawing, by hand, in a practicalexerciseIndustry Training Authority14
Program ContentLevel 1LINE (GAC):CUSE APPLIED MATHEMATICSCompetency:C7Solve problems involving trigonometryObjectivesTo be competent in this area, the individual must be able to solve complex trigonometric problems relatedto tool and die making.LEARNING TASKSCONTENT1. Solve complex trigonometric problems related todesigning and making tools and dies Using rollers and pins to measuredimensions Calculating angles Tool and Die Maker08/13 A slider with feathered edges Compound angles Amount of draft over a given angleCreating construction surfacesIndustry Training Authority15
Program ContentLevel 1LINE (GAC):DUSE MEASURING TOOLSCompetency:D6Inspect workpiecesObjectivesTo be competent in this area, the individual must be able to inspect a finished workpiece.LEARNING TASKSCONTENT1. Describe the inspection of finished workpieces Required dimensions 2. Apply inspection techniquesTool and Die Maker08/13Required accuracy of dimensions Considerations of temperature controland variance Geometric dimensioning and tolerancing Inspection equipment Optical comparators Master square Linear height gauge Coordinate measuring machines High precision micrometer Manual measurements Inspection grade gauge blocks andpins Toolmaker’s microscope Use inspection tools and equipment (asabove) in practical shop exercises Measuring pockets (cavities) High precision measuring standards Using rollers and pins for measurementIndustry Training Authority16
Program ContentLevel 1LINE (GAC):FSELECT MATERIALSCompetency:F5Select materials for applicationsObjectivesTo be competent in this area, the individual must be able to select materials for tooling applications.LEARNING TASKSCONTENT 1. Describe tooling materialsTypes of tooling materials 2. Select materials for specific applicationsTool and Die Maker08/13Alloy compositionsStandards for materials DIN SAE Manufacturers’ specifications Materials identification numbers andnames Tooling applications Mould materials Hard Flexible Punch materials Die materials Given a set of specifications, selectappropriate materials in a practical shopexerciseIndustry Training Authority17
Program ContentLevel 1LINE (GAC):FSELECT MATERIALSCompetency:F7Describe materials testingObjectivesTo be competent in this area, the individual must be able to: Describe non-destructive testing processes. Conduct non-destructive testing processes.LEARNING TASKSCONTENT1. Describe non-destructive testing techniques2. Conduct non-destructive testingTool and Die Maker08/13 Dye penetrant Magnetic particle inspection Given specific requirements, conductnon-destructive tests in a practical shopexerciseIndustry Training Authority18
Program ContentLevel 1LINE (GAC):GPLAN SEQUENCE OF OPERATIONCompetency:G5Deburr workpiecesObjectivesTo be competent in this area, the individual must be able to deburr a workpiece.LEARNING TASKS1. Use various deburring tools2. Remove burrs from a workpieceTool and Die Maker08/13CONTENT Files Rotary deburring tools Scrapers Abrasive stones Polish requirements Deburring techniques Assess workpiece Identify burrs Rough edges Given specifications, identify criticaledges and define deburringrequirements in a practical shopexercise Remove burrs to meet specificationsIndustry Training Authority19
Program ContentLevel 1LINE (GAC):IUSE DRILLING MACHINESCompetency:I4Perform drilling processes for tool and die makingObjectivesTo be competent in this area, the individual must be able to perform specialized drilling processes for tooland die making.LEARNING TASKSCONTENT1. Identify drilling requirements for materials used intool and die making Materials used in tool and die making Special drilling tools and requirements 2. Perform deep hole drilling Small hole requirements Depth of tapping Depth of chamfers Water cooling lines Thread cutting for die blocks Tool and Die Maker08/13Jig boring machineIndustry Training AuthorityCountersinking20
Program ContentLevel 1LINE (GAC):KUSE LATHESCompetency:K5Describe the use of advanced cutting toolsObjectivesTo be competent in this area, the individual must be able to: Describe the use of advanced cutting tools for tool and die making. Make tools and dies using advanced cutting tools.LEARNING TASKSCONTENT1. Describe the use of advanced cutting tools in tooland die making2. Use advanced cutting tools in tool and die makingTool and Die Maker08/13 Concentricity Turning a hardened cavity Taper locks Special tools Tool post grinder Given a set of specifications, fabricatetools and dies using advanced cuttingtools in a practical shop exerciseIndustry Training Authority21
Program ContentLevel 1LINE (GAC):LUSE MILLING MACHINESCompetency:L5Mill pockets and profiles for tool and die makingObjectivesTo be competent in this area, the individual must be able to: Describe pocket milling in tool and die making. Describe profile milling in tool and die making. Mill pockets and profiles in tool and die making.LEARNING TASKS1. Describe milling pockets and profilesCONTENT Alignment considerations in tool anddie making Pocketing for functionality of toolmaking Machining special materials Hardened tool steel EDM Electrodes Profiling calculations Pocketing Square Strength Recognize functionality of pocket2. Mill profiles and inserts Given a set of specifications, millprofiles and inserts in practical shopexercises3. Mill pockets Given a set of specifications, millpockets in a practical shop exercisesTool and Die Maker08/13Industry Training Authority22
Program ContentLevel 1LINE (GA
Tool and Die Maker Industry Training Authority 8 Tool & Die Outline August 2013 Occupational Analysis Chart TOOL AND DIE MAKER Occupational Description: “Tool and Die Maker” means a person who makes, repairs and tests dies, cutting tools, jigs, fixtures, moulds, gauges and
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