Manufacture Production Tooling from Drawings or Samples Training

Objectives:
• Understand the scope of manufacturing tooling in production environments
• Identify common types of tooling such as jigs, fixtures, dies, and moulds
• Recognize workplace health and safety requirements related to tooling manufacture
• Interpret basic safety signs and symbols
• Apply personal protective equipment (PPE) correctly

Topics:
• Overview of manufacturing tooling: jigs, fixtures, dies, moulds, gauges
• Role of tooling in production efficiency and quality
• Introduction to the South African National Standards (SANS) and OHS Act
• Safety precautions when handling materials and operating machinery
• PPE requirements and proper usage
• Housekeeping and hazard identification in the workshop

Objectives:
• Identify drawing types: orthographic, isometric, section views
• Understand title blocks, dimensions, tolerances, and symbols
• Interpret material specifications and surface finish symbols
• Recognize welding symbols and thread notations

Topics:
• Types of engineering drawings: orthographic projection, isometric, exploded views
• Components of a drawing: title block, scale, revision table
• Dimensioning systems: linear, angular, and geometric tolerances
• Standard symbols: surface finish, welding, machining
• Material specifications and abbreviations
• Reading assembly drawings and part lists

Objectives:
• Define tolerance, allowance, and fit types
• Interpret ISO tolerance grades and fundamental deviations
• Calculate limit dimensions and fits
• Apply tolerance concepts to tooling design

Topics:
• Basic concepts: tolerance, allowance, clearance, interference
• ISO system of limits and fits: hole-basis and shaft-basis
• Tolerance grades (IT01 to IT18) and fundamental deviations
• Calculating maximum and minimum dimensions
• Selecting appropriate fits for tooling components
• Practical examples: press fits, sliding fits, running fits

Objectives:
• Identify common ferrous and non-ferrous materials for tooling
• Understand material properties: hardness, toughness, wear resistance
• Select appropriate materials based on application
• Recognize heat treatment processes and their effects

Topics:
• Ferrous materials: carbon steel, alloy steel, tool steel, cast iron
• Non-ferrous materials: aluminium, brass, bronze, carbide
• Material properties: hardness, tensile strength, ductility
• Heat treatment: annealing, normalising, hardening, tempering
• Surface treatments: nitriding, carburising, plating
• Material selection criteria for jigs, fixtures, dies, and moulds

Objectives:
• Identify precision measuring instruments: callipers, micrometres, gauges
• Demonstrate correct usage and care of measuring tools
• Perform measurements to specified tolerances
• Record and interpret measurement data

Topics:
• Vernier callipers: reading and measurement techniques
• Micrometres: outside, inside, depth types
• Dial indicators and height gauges
• Gauge blocks and slip gauges
• Go/No-go gauges for thread and hole inspection
• Care, calibration, and storage of instruments
• Recording measurements and interpreting results

Objectives:
• Describe basic machining operations: turning, milling, drilling, grinding
• Identify machine tools and their applications
• Understand cutting tool materials and geometries
• Apply safe operating procedures for machine tools

Topics:
• Overview of machining processes: turning, milling, drilling, grinding, shaping
• Machine tools: lathe, milling machine, drill press, surface grinder
• Cutting tool materials: high-speed steel, carbide, ceramics
• Cutting tool geometry: rake angle, clearance angle, cutting edge
• Workholding: chucks, collets, vises
• Machine safety: guards, emergency stops, chip handling

Objectives:
• Set up a lathe for turning operations
• Perform straight turning, facing, and chamfering
• Measure and verify dimensions
• Apply cutting speeds and feeds appropriately

Topics:
• Lathe components: headstock, tailstock, carriage, tool post
• Workholding: three-jaw chuck, four-jaw chuck, centres
• Cutting tool selection and mounting
• Turning parameters: cutting speed, feed rate, depth of cut
• Operations: straight turning, facing, chamfering, grooving
• Measuring finished diameters and lengths
• Troubleshooting common turning issues

Objectives:
• Set up a milling machine for basic operations
• Perform face milling, peripheral milling, and slot cutting
• Use dividing head for indexing
• Inspect milled surfaces

Topics:
• Milling machine types: vertical, horizontal, universal
• Workholding: vise, clamps, indexing head
• Milling cutters: end mills, face mills, slot drills
• Cutting parameters: spindle speed, feed, depth of cut
• Operations: face milling, side milling, slotting, drilling
• Indexing: direct, simple, differential
• Inspection of flatness, squareness, and surface finish

Objectives:
• Select appropriate drills and taps for material and thread type
• Perform drilling, countersinking, and counterboring
• Cut internal and external threads
• Inspect threads using gauges

Topics:
• Twist drill geometry and nomenclature
• Drilling operations: centre drilling, through holes, blind holes
• Countersinking and counterboring tools
• Thread types: metric, unified, Whitworth
• Tapping: hand taps, machine tapping, tap selection
• Die threading for external threads
• Thread inspection: plug gauges, ring gauges, thread micrometers

Objectives:
• Identify grinding wheel types and specifications
• Perform surface grinding and cylindrical grinding
• Achieve required surface finish and tolerances
• Apply deburring and polishing techniques

Topics:
• Grinding wheel marking system: abrasive, grit, grade, bond
• Surface grinding: set-up, wheel dressing, stock removal
• Cylindrical grinding: between centres, chucking
• Grinding parameters: wheel speed, work speed, depth of cut
• Surface finish measurement: Ra, Rz
• Deburring: manual and mechanical methods
• Polishing and lapping for fine finishes

Objectives:
• Understand CNC machine components and axes
• Write basic G-code programs for turning and milling
• Simulate programs for error checking
• Set up and run a simple CNC operation

Topics:
• CNC machine types: lathes, milling machines, machining centres
• Coordinate systems: machine zero, workpiece zero, absolute/incremental
• G-code basics: G00, G01, G02, G03, G90, G91
• M-code basics: M03, M05, M06, M08, M09, M30
• Tool offsets and tool length compensation
• Program simulation and verification
• Safety: interlock, emergency stop, program dry run

Objectives:
• Define the purpose of jigs and fixtures
• Identify locating and clamping principles
• Design simple jigs and fixtures for drilling and milling
• Select standard components: bushes, clamps, base plates

Topics:
• Functions of jigs and fixtures: accuracy, repeatability, interchangeability
• Locating principles: 3-2-1 rule, datum features
• Clamping principles: force direction, clamping mechanisms
• Types of jigs: template, plate, channel, box jigs
• Types of fixtures: milling, turning, grinding fixtures
• Standard components: drill bushes, toggle clamps, locating pins
• Design considerations: chip clearance, loading/unloading, rigidity

Objectives:
• Describe types of dies: blanking, piercing, bending, drawing
• Understand die components: punch, die block, stripper
• Calculate clearance and cutting forces
• Assemble and align a simple die set

Topics:
• Die types: blanking, piercing, progressive, compound, bending, drawing
• Die components: punch, die block, stripper plate, guide pins
• Clearance calculation: material thickness and shear strength
• Cutting force estimation
• Die materials and heat treatment
• Die set assembly: alignment, fastening, shimming
• Safety: handling sharp edges, spring-loaded strippers

Objectives:
• Describe injection moulding and compression moulding processes
• Identify mould components: cavity, core, ejector system
• Understand draft angles, parting lines, and cooling channels
• Assemble a simple two-plate mould

Topics:
• Moulding processes: injection, compression, transfer, blow moulding
• Mould types: two-plate, three-plate, hot runner
• Mould components: cavity, core, sprue, runner, gate, ejector pins
• Draft angles and surface finish requirements
• Cooling system design: channels, baffles, bubblers
• Mould materials: tool steel, aluminium, beryllium copper
• Assembly: dowel pins, screws, alignment rings

Objectives:
• Assemble tooling components according to drawings
• Fit and align parts using hand tools and measuring instruments
• Apply shimming and adjustment techniques
• Verify assembly accuracy

Topics:
• Assembly procedures: sequence, cleanliness, lubrication
• Fitting techniques: filing, scraping, lapping
• Alignment: using dial indicators, squares, straight edges
• Shimming: materials, thickness selection
• Fastening: bolts, dowels, set screws, adhesives
• Inspection of assembled tooling: parallelism, perpendicularity
• Documentation: assembly records, non-conformance reports

Objectives:
• Conduct functional tests of assembled tooling
• Identify and rectify defects such as misalignment or poor finish
• Perform trial runs to produce sample parts
• Document test results and modifications

Topics:
• Functional testing: moving parts, clearances, clamping forces
• Trial run: machine setup, material preparation, safety checks
• Inspection of trial parts: dimensional accuracy, surface finish
• Common defects: burrs, scratches, misalignment, flash
• Troubleshooting: adjusting clearances, modifying components
• Documentation: test reports, change requests, sign-off

Objectives:
• Apply quality control procedures for tooling manufacture
• Use inspection equipment to verify conformance to specifications
• Interpret inspection reports and identify non-conformances
• Implement corrective actions

Topics:
• Quality control plan: inspection points, sampling, acceptance criteria
• Inspection techniques: coordinate measuring machines (CMM), optical comparators
• Surface roughness measurement: profilometers
• Hardness testing: Rockwell, Brinell, Vickers
• Non-destructive testing: dye penetrant, magnetic particle
• Statistical process control basics: control charts
• Corrective actions: rework, scrap, design change

Objectives:
• Identify common wear mechanisms in tooling
• Perform preventive maintenance on tooling components
• Repair damaged tooling using welding, machining, or replacement
• Document maintenance activities

Topics:
• Wear mechanisms: abrasive, adhesive, fatigue, corrosion
• Preventive maintenance: cleaning, lubrication, inspection schedule
• Repair techniques: welding (TIG, MIG), build-up, machining
• Replacement of worn components: bushes, pilots, inserts
• Sharpening and reconditioning of cutting edges
• Maintenance records: logbooks, checklists, spares inventory

Objectives:
• Analyse complex tooling problems and develop solutions
• Apply lean manufacturing principles to tooling production
• Optimise tooling design for cost and efficiency
• Present case studies of tooling improvements

Topics:
• Root cause analysis: fishbone diagram, 5 Whys
• Lean principles: 5S, value stream mapping, waste reduction
• Design for manufacturability (DFM) in tooling
• Cost estimation: material, labour, overhead
• Case studies: reducing cycle time, improving tool life
• Emerging technologies: additive manufacturing, automation
• Problem-solving workshop: real-world scenarios

Objectives:
• Demonstrate competency in tooling manufacture from drawings or samples
• Complete a practical assessment: produce a simple tooling item
• Review key concepts and address gaps
• Receive feedback and certification guidance

Topics:
• Review of all topics: safety, drawings, machining, assembly, quality
• Practical assessment: interpret drawing, plan operations, manufacture component, inspect
• Written test: theory, calculations, problem solving
• Feedback session: strengths, areas for improvement
• Certification requirements: portfolio of evidence, logbook
• Career pathways in tooling and die making