FABRICATION AND WELDING PRACTICE
ABC Level 1 Certificate in Fabrication and Welding Practice 600/5178/4
Work Book
for
Unit A/600/0558 Fabrication of Thick Plate
Level 1
Version 2 - July 2013
Learner Name ......
Name of Centre where registered ......
ABC Registration I/D ......
This booklet provides questions and practical tasks for learners linked to the Assessment Criteria for Unit A/600/0558 Fabrication of Thick Plate Level 1.
It is an Optional Unit in the ABC Level 1 Certificate in Fabrication and Welding Practice 600/5178/4.
All questions and tasks identify the Assessment Criteria they link to and appear in brackets e.g.
(AC 2.1).
Successful completion of all the questions and tasks will provide all the evidence needed for the unit.
Centres can use these as they wish. Learners could complete them at their own pace, at a pace directed by the centre or under test conditions.
Whichever method is selected, it is important that learners are given information and support prior to being given assessment tasks.
Assessors will need to make a judgement as to whether a learner has successfully completed each task.
All evidence must be the learner’s own work.
It is important that Health and Safety is an integral part of every unit that a learner will study in the ABC Level 1 Certificate in Fabrication and Welding Practice.
PLEASE NOTE
It is not mandatory to use the booklet. Centres may wish to provide their own assessment tasks, but they must ensure that learners are able to provide evidence of achievement of all Learning Outcomes and Assessment Criteria for this unit.
Aims:
Learn how to handle materials, identify and use tools safely, mark out, cut and form materials over
3 mm in thickness
Objectives:
· Know about handling materials
· Know about marking out tools
· Understand the principles of marking out
· Know about basic hand tools
· Know about hand/powered machines
1. Describe the safety features that should be followed when moving and handling sheet metal and fabricated materials in the workshop (AC1.1)
2. Sketch a typical safe storage system for sheet and/or plate (AC1.1)
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1. Identify common marking out tools (AC 2:1)
Marking out instrument/tool / Name of instrument/tool / Use/purpose
Marking out instrument/tool / Name of instrument/
tool / Use/purpose
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2. Describe the main purpose of the following marking out tools (AC 2:1)
Nipple punch
Back-mark gauge
Odd-leg callipers
3. List the tools/instruments used to mark out the following (AC 2:1)
Straight lines
Parallel lines
Circumferences
Lines 90° to each other
1. (AC 3.1) Explain the principles of marking out with reference to:
Datum line marking
Progressive marking
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1. Identify the following hand tools and their uses (AC 4:1)
Hand tool / Name of hand tool / Use/purposeHand tool / Name of hand tool / Use/purpose
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2. Identify common portable power tools and their uses (AC 4:2)
Type of power tool / Application and use of the power toolPortable hand held drill
Polishing machine
Hand held portable grinding machine
3. Identify portable and fixed grinding tools (AC 4:3)
Type of grinder / Application and use of the grinderStraight grinder
Angle grinder
Pedestal grinder
1. Identify the following hand/powered machines (AC 5:1)
Type of hand/powered machine / Typical applicationsBench Shears
Powered Guillotine
Mechanical Saw
Type of drilling machine / Typical applications
Pillar Drill
Radial Arm Drill
Identify manual thermal cutting using the oxy/fuel gas process (AC 6:1)
1. Observe the oxy/fuel gas cutting process and record the required information:
Evidence to show observation of manual thermal cutting using the oxy/fuel gas cutting processDate: / Plate thickness
Nozzle size
Fuel gas pressure
Oxygen pressure
Type of flame setting / ...... mm
...... mm
...... bar
...... bar
......
2. State the importance of using a clean nozzle, correct nozzle size, correct gas pressures, stand-off and pre-heating when using thermal cutting equipment
(AC 6:1)
1. Complete the table below relating to manual and powered forming machines (
(AC 7:1)
Type of manual folding machine / Typical applicationsBox and pan folder
Fly press
Type of powered folding machine / Typical applications
Press brake
Locate, identify and write down the typical information given on the instruction plate of a folding machine (AC 7:1)
Type of Machine:
1. What is meant by “spring-back” which may occur when rolling or bending a piece of metal (AC8.1)
2. Explain why a bending sequence must be used when bending or folding intricate shapes of metal (AC8.1)
Draw a cross sectional view of the position of the rolls for the following rolling machines (AC 9:1)
Initial pinch rolls
Pyramid rolls
1. For each form of metal supply listed below (AC 10.1)
· produce one neat pictorial sketch
· indicate one typical application that it can be used for
A. Sheet
Sketch / ApplicationB. Plate
Sketch / ApplicationC. Slab
Sketch / Application2. For each form of metal supply listed as d, e, f, g, h, and i.
· draw a typical cross section
· indicate one typical application that it can be used for
D. Universal beam
Sketch / ApplicationE. Universal column
Sketch/ Application
F. Equal and unequal angle
Sketch / ApplicationG. Rolled steel channel
Sketch/ Application
H. Rolled steel joist
Sketch / ApplicationI. Rolled steel tee
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Identify assembly aids. (AC 11:1) For EACH assembly aid listed, state a typical application where it may be used in the
assembly of thick plate fabrication work
Assembly Aid / Typical applicationDrifts
Cleats
Wedges
Clamps
Dogs
Podger spanner
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(AC 12:1) For the three given fabrication applications state in each case:
(a) Tools/equipment used to carry out inspection
(b) Main features of the application that require inspection
Application No 1: A rolled cylinder
Tools/equipment used to carry out inspection
Main features of the application that require inspection
Application No 2: A 90º bend in 3 mm thick plate
Tools/equipment used to carry out inspection
Main features of the application that require inspection
Application No 3: A simple fabricated bracket in 6 mm thick plate
Tools/equipment used to carry out inspection
Main features of the application that require inspection
Before starting the Practical Fabrication Task:
1. Demonstrate how to fit a new hacksaw blade into a frame.
2. Demonstrate how to how to use a cold chisel in a safe manner.
3. Demonstrate the correct procedure for using clamps.
Observation of the tutor:
4. Observe a demonstration showing material spring-back.
5. Observe a demonstration of a bend sequence.
6. Observe the production of holes using a portable electric drill hand drill.
7. Observe the production of bevels using powered machinery.
8. Observe a demonstration of straight, curved and bevel manual cutting using
thermal or mechanical processes.
Selection of tools and equipment:
9. Select all the tools required for the fabrication task.
10. List all safety precautions that which need to be considered before using the
equipment required for the task. (Safety task sheet)
MAKE SURE ALL OF THE ABOVE REQUIREMENTS ARE COMPLETED BEFORE STARTING THE FABRICATION TASK.
Safety task sheetList all safety precautions that which need to be considered before using the
equipment required for the task
Hand tools/equipment used / Safety requirements that should be observed
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Learner’s Name:......
PRACTICAL TASKS / Achieved / Not Achieved1. Sketch a typical safe storage system for sheet and/or plate.
(AC 1:1)
2. Select the correct tools, and mark out onto plate or sheet or template card, a circle of 85mm diameter to a tolerance of ± 0.5 mm. (AC 2:1)
3. Set out a datum line, from that datum line mark out six centres 25-mm pitch. Check and record the overall accuracy. (AC 2:2)
4. From a datum, draw two parallel lines 25 mm apart and 100 mm long. Check and record accuracy. (AC 2:2)
5. Demonstrate how to fit a new blade into a hacksaw frame correctly. (AC 4:1)
6. Demonstrate the correct technique to safely use a cold chisel. (AC 4:1)
7. Observe the production of holes using a portable electric hand drill. (AC 5:1)
8. Observe the production of bevels using powered machinery.
(AC 5:1)
9. Locate and identify the maximum capacity instruction plate on the listed equipment. Describe the operating principles of each machine and list any safety devices fitted. (AC 5:1)
10 List all safety precautions which need to be considered when using the listed equipment. (AC 5:1)
11. Observe a demonstration of straight, curved and bevel manual cutting using thermal or mechanical processes. (AC 6:1)
12. Indicate the importance of using a clean nozzle, correct nozzle size, correct gas pressures, stand-off and pre-heating when using thermal cutting equipment. (AC 6:1)
13. Locate, identify and write down the typical information given on the instruction plate on a folding machine. (AC 7:1)
14. Observe a demonstration showing material spring-back.
(AC 8:1)
15. Observe a demonstration of bend sequence. (AC 8:1)
16. Sketch the roll configuration for:
(a) initial pinch rolls (b) pyramid rolls (AC 9:1)
17. For each form of metal supply listed in Assessment Criteria 10.1, undertake the following:
(a) produce one neat pictorial sketch
(b) produce one typical cross section
(c) indicate one typical application that it can be used for (AC 10:1)
18. Carry out the correct procedure for using clamps. (AC 11:1)
19. Identify three of the assembly aids listed in AC 11.1 (AC 11:1)
20. List appropriate inspection and quality control methods for three stated applications List all safety precautions that which need to be considered before using the equipment required for the task. (Safety task sheet) (AC 12:1)
Course tutor feedback comments
Signature: Date:
If chosen for sampling, Internal/External Moderators must complete the following:
INTERNAL MODERATOR’S NAME:Comment
Signature: Date:
EXTERNAL MODERATOR’S NAME:
Comment
Signature: Date:
Authenticity Statement
DECLARATION OF AUTHENTICITY
This declaration must be completed and signed by the learner and countersigned by the tutor/assessor.
Learner Name: …………..……………….……………………………………………………
Learner Number: ………………………………………………………………………………
Centre: …………………………………………………………………………………………
Learner Statement of Authenticity
I confirm that the attached assignment/portfolio is all my own work* and does not include any work completed by anyone other than myself. I have completed the assignment/portfolio in accordance with the Awarding Body instructions and within the time limits set by my Centre.
Signature: ………………………………….. Date: ………………………………
Centre Confirmation of Authenticity
On behalf of ……………………………………. (insert centre name), I confirm that the above mentioned learner, to the best of my knowledge, is the sole author of the completed assignment/portfolio attached.
Signed: ……………………………………. Date: ………………………………
Name: ……………………………………..
Job Description: ………………………………………………………………………………
*Unless otherwise stated e.g. for some entry level qualifications learner can work together but should show sections which are their own work.
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