BTEC Assignment Brief
Pearson BTEC Level 3 National Foundation Diploma in Engineering
Pearson BTEC Level 3 National Diploma in Engineering
Pearson BTEC Level 3 National Diploma in Electrical and Electronic
Engineering
Pearson BTEC Level 3 National Diploma in Mechanical Engineering
Pearson BTEC Level 3 National Diploma in Computer Engineering
Pearson BTEC Level 3 National Diploma in Manufacturing Engineering
Pearson BTEC Level 3 National Diploma in Aeronautical Engineering
Pearson BTEC Level 3 National Extended Diploma in Engineering
Qualification
Pearson BTEC Level 3 National Extended Diploma in Electrical and
Electronic Engineering
Pearson BTEC Level 3 National Extended Diploma in Mechanical
Engineering
Pearson BTEC Level 3 National Extended Diploma in Computer
Engineering
Pearson BTEC Level 3 National Extended Diploma in Manufacturing
Engineering
Pearson BTEC Level 3 National Extended Diploma in Aeronautical
Engineering
Unit number
Unit 43: Manufacturing Computer Numerical Control Machining
and title
Processes
Student Name
Assignment
Using CNC machinery to manufacture a component
title
Assessor Z.Rushiti
Issue date W/C 07.11.2022
Hand in
W/C 09.01.2023
deadline
You are working as a trainee CNC operator for a company that
manufactures complex components that would be difficult to
manufacture using traditional methods.
Vocational
Scenario or Your supervisor is pleased with your level of understanding associated
Context with how CNC machines are controlled and programmed, and would
now like you to demonstrate that you can develop a CNC part-
program, simulate the program and then manufacture the
component. A customer is waiting for the said component.
You have been asked to demonstrate the practical skills needed to
program, set-up and use a CNC machine to manufacture a component
Task 1 that requires at least six complex machining processes and at least
three different cutting tools. You will be provided with a drawing.
To do this:
, You will generate a portfolio of evidence in a log book that shows that
you can create a CNC set-up sheet and part program, simulate the
program and then carry out a CNC machining activity to manufacture
the component safely and accurately.
Your CNC machine tool set-up sheet must include detailed but concise
and accurate information about:
• Tooling parameters, such as feed rates, cutting speeds
(including RPM calculations), roughing operations, finishing
operations, tooling diameters, cutter compensation, tooling
materials and tool numbers
• Component parameters, including calculations, materials and
the suitability of the machine to achieve the required
tolerances and surface textures
• Work holding methods/parameters
• Tool change positions, tool mounting and tool offsets
• Machine and program datums
• Safe positioning for machining
• Sustainability considerations, including the separation/disposal
of materials and the use of resources.
You then need to:
• Develop a part program to manufacture a component safely
and accurately, by using auxiliary functions, CNC codes and
sub-routines/programs
• Simulate the part program/machining process using graphical
software to check for syntax/logical errors and the tool cutter
paths
• Modify the program as required to make it more
efficient/accurate
• Set-up safely the CNC machine, including the work holding
devices and machine parameters, and simulate the physical
machining of the component, correcting any syntax/logical
errors and editing the part program to make sure it is as
effective/efficient as it can be
• Undertake quality control checks for dimensional tolerance,
surface texture, angles and also hole details and make further
adjustments to the work holding and machining parameters as
required to improve the effectiveness/efficiency of the
machining process
• Manufacture the component safely, record what was done and
then remove the swarf and the workpiece from the machine
2
BTEC Assignment Brief v1.0
BTEC Internal Assessment QDAM January 2015
,Checklist of Preparation activities and documents (contained in a log book) prior
evidence to CNC machining a component, to include: machine tool set-up sheet
required and a computer part program, and simulation of the program.
Input the part program and set up the CNC machine, to produce a
component, using multiple tooling. Quality control checks recorded on
documentation to verify that the component meets the specification
and is fit for the intended purpose.
The evidence for the practical activity should include learner
observation records/witness statements and annotated
photographs/drawings.
Criteria covered by this task:
Unit/Criteria
To achieve the criteria you must show that you are able to:
reference
43/BC.D2 Optimise the processes to effectively and efficiently develop and
manufacture safely a component using at least six complex CNC
processes and at least three different cutting tools
43/B.M2 Produce an accurate machine tool set-up sheet for a component using at
least six complex CNC processes and at least three different cutting
tools
43/B.M3 Create a part program to machine a component safely and efficiently,
using at least six complex CNC processes and at least three different
cutting tools and simulate for any syntax and logical errors
Manufacture accurately, a component using at least six complex CNC
43/C.M4 processes and at least three different cutting tools, incorporating
improvements from the simulation
Create a machine tool set-up sheet for a component using at least six
43/B.P2 complex CNC processes and at least three different cutting tools
Create a part program to machine a component safely using at least six
43/B.P3 complex CNC processes and at least three different cutting tools and
simulate for any syntax and logical errors
Simulate the CNC machining of a component safely, correcting any
43/C.P4 syntax and logical errors
Manufacture a component safely using at least six complex CNC
43/C.P5 processes and at least three different cutting tools
Sources of Books
information to
Smid P; CNC Programming Handbook, 3rd Edition (Industrial Press,
support you
2007); ISBN 9780831133474.
with this
Assignment Smid P; CNC setup for Milling and Turning: Mastering CNC Control
Systems (Industrial Press Inc., 2010) ISBN 9780831133504
3
BTEC Assignment Brief v1.0
BTEC Internal Assessment QDAM January 2015
, Websites
www.haas.co.uk
http://website.denford.ltd.uk
www.techsoft.co.uk
www.fanuc.eu/uk/en
www.heidenhain.co.uk
Other
assessment
materials
attached to
this
Assignment
Brief
4
BTEC Assignment Brief v1.0
BTEC Internal Assessment QDAM January 2015
, 5
BTEC Assignment Brief v1.0
BTEC Internal Assessment QDAM January 2015
, Operators Information Sheet
Name: - Course: BTEC Date: 21/04/22
Program Number: Interpret Drawing: Number of blocks:
Surface Finish Surface Finish of 125 micro inches
Tolerances Tolerance +- 0.15mm
Cutter:
Material: Workpiece: Aluminium
HSS/CARBIDE
Datum Point:
X0
Y0
Z0
Methods of Manufacture
Work holding
Machine vice and Fixture Plate
Device:
Coolant: Coolant Flood
Cutters used: T1 8.5mm Twist drill 2 teeth HSS
T2 8mm end mill 4 HSS
T3 8mm slot mill 2 HSS
T4 100mm facing of tool 5 Carbide
T5 8mm flat mill 3 HSS
16mm large
T6 4 HSS
diameter flat mill
Pearson BTEC Level 3 National Foundation Diploma in Engineering
Pearson BTEC Level 3 National Diploma in Engineering
Pearson BTEC Level 3 National Diploma in Electrical and Electronic
Engineering
Pearson BTEC Level 3 National Diploma in Mechanical Engineering
Pearson BTEC Level 3 National Diploma in Computer Engineering
Pearson BTEC Level 3 National Diploma in Manufacturing Engineering
Pearson BTEC Level 3 National Diploma in Aeronautical Engineering
Pearson BTEC Level 3 National Extended Diploma in Engineering
Qualification
Pearson BTEC Level 3 National Extended Diploma in Electrical and
Electronic Engineering
Pearson BTEC Level 3 National Extended Diploma in Mechanical
Engineering
Pearson BTEC Level 3 National Extended Diploma in Computer
Engineering
Pearson BTEC Level 3 National Extended Diploma in Manufacturing
Engineering
Pearson BTEC Level 3 National Extended Diploma in Aeronautical
Engineering
Unit number
Unit 43: Manufacturing Computer Numerical Control Machining
and title
Processes
Student Name
Assignment
Using CNC machinery to manufacture a component
title
Assessor Z.Rushiti
Issue date W/C 07.11.2022
Hand in
W/C 09.01.2023
deadline
You are working as a trainee CNC operator for a company that
manufactures complex components that would be difficult to
manufacture using traditional methods.
Vocational
Scenario or Your supervisor is pleased with your level of understanding associated
Context with how CNC machines are controlled and programmed, and would
now like you to demonstrate that you can develop a CNC part-
program, simulate the program and then manufacture the
component. A customer is waiting for the said component.
You have been asked to demonstrate the practical skills needed to
program, set-up and use a CNC machine to manufacture a component
Task 1 that requires at least six complex machining processes and at least
three different cutting tools. You will be provided with a drawing.
To do this:
, You will generate a portfolio of evidence in a log book that shows that
you can create a CNC set-up sheet and part program, simulate the
program and then carry out a CNC machining activity to manufacture
the component safely and accurately.
Your CNC machine tool set-up sheet must include detailed but concise
and accurate information about:
• Tooling parameters, such as feed rates, cutting speeds
(including RPM calculations), roughing operations, finishing
operations, tooling diameters, cutter compensation, tooling
materials and tool numbers
• Component parameters, including calculations, materials and
the suitability of the machine to achieve the required
tolerances and surface textures
• Work holding methods/parameters
• Tool change positions, tool mounting and tool offsets
• Machine and program datums
• Safe positioning for machining
• Sustainability considerations, including the separation/disposal
of materials and the use of resources.
You then need to:
• Develop a part program to manufacture a component safely
and accurately, by using auxiliary functions, CNC codes and
sub-routines/programs
• Simulate the part program/machining process using graphical
software to check for syntax/logical errors and the tool cutter
paths
• Modify the program as required to make it more
efficient/accurate
• Set-up safely the CNC machine, including the work holding
devices and machine parameters, and simulate the physical
machining of the component, correcting any syntax/logical
errors and editing the part program to make sure it is as
effective/efficient as it can be
• Undertake quality control checks for dimensional tolerance,
surface texture, angles and also hole details and make further
adjustments to the work holding and machining parameters as
required to improve the effectiveness/efficiency of the
machining process
• Manufacture the component safely, record what was done and
then remove the swarf and the workpiece from the machine
2
BTEC Assignment Brief v1.0
BTEC Internal Assessment QDAM January 2015
,Checklist of Preparation activities and documents (contained in a log book) prior
evidence to CNC machining a component, to include: machine tool set-up sheet
required and a computer part program, and simulation of the program.
Input the part program and set up the CNC machine, to produce a
component, using multiple tooling. Quality control checks recorded on
documentation to verify that the component meets the specification
and is fit for the intended purpose.
The evidence for the practical activity should include learner
observation records/witness statements and annotated
photographs/drawings.
Criteria covered by this task:
Unit/Criteria
To achieve the criteria you must show that you are able to:
reference
43/BC.D2 Optimise the processes to effectively and efficiently develop and
manufacture safely a component using at least six complex CNC
processes and at least three different cutting tools
43/B.M2 Produce an accurate machine tool set-up sheet for a component using at
least six complex CNC processes and at least three different cutting
tools
43/B.M3 Create a part program to machine a component safely and efficiently,
using at least six complex CNC processes and at least three different
cutting tools and simulate for any syntax and logical errors
Manufacture accurately, a component using at least six complex CNC
43/C.M4 processes and at least three different cutting tools, incorporating
improvements from the simulation
Create a machine tool set-up sheet for a component using at least six
43/B.P2 complex CNC processes and at least three different cutting tools
Create a part program to machine a component safely using at least six
43/B.P3 complex CNC processes and at least three different cutting tools and
simulate for any syntax and logical errors
Simulate the CNC machining of a component safely, correcting any
43/C.P4 syntax and logical errors
Manufacture a component safely using at least six complex CNC
43/C.P5 processes and at least three different cutting tools
Sources of Books
information to
Smid P; CNC Programming Handbook, 3rd Edition (Industrial Press,
support you
2007); ISBN 9780831133474.
with this
Assignment Smid P; CNC setup for Milling and Turning: Mastering CNC Control
Systems (Industrial Press Inc., 2010) ISBN 9780831133504
3
BTEC Assignment Brief v1.0
BTEC Internal Assessment QDAM January 2015
, Websites
www.haas.co.uk
http://website.denford.ltd.uk
www.techsoft.co.uk
www.fanuc.eu/uk/en
www.heidenhain.co.uk
Other
assessment
materials
attached to
this
Assignment
Brief
4
BTEC Assignment Brief v1.0
BTEC Internal Assessment QDAM January 2015
, 5
BTEC Assignment Brief v1.0
BTEC Internal Assessment QDAM January 2015
, Operators Information Sheet
Name: - Course: BTEC Date: 21/04/22
Program Number: Interpret Drawing: Number of blocks:
Surface Finish Surface Finish of 125 micro inches
Tolerances Tolerance +- 0.15mm
Cutter:
Material: Workpiece: Aluminium
HSS/CARBIDE
Datum Point:
X0
Y0
Z0
Methods of Manufacture
Work holding
Machine vice and Fixture Plate
Device:
Coolant: Coolant Flood
Cutters used: T1 8.5mm Twist drill 2 teeth HSS
T2 8mm end mill 4 HSS
T3 8mm slot mill 2 HSS
T4 100mm facing of tool 5 Carbide
T5 8mm flat mill 3 HSS
16mm large
T6 4 HSS
diameter flat mill
