MEM05010_AT1_BA_TQM_v1 (4).docx

Unit Code/s & Name/s MEM05010 Apply fabrication, forming and shaping techniques Cluster Name\ *If applicable* N/A Assessment Type ☐ Written ☒ Knowledge Questions ☐ Portfolio of Evidence Assessment Name Final Theory Quiz (WPL) Assessment Task No. 1 of 3 +------------------------------------...

Unit Code/s & Name/s MEM05010 Apply fabrication, forming and shaping techniques Cluster Name\ *If applicable* N/A Assessment Type ☐ Written ☒ Knowledge Questions ☐ Portfolio of Evidence Assessment Name Final Theory Quiz (WPL) Assessment Task No. 1 of 3 +-----------------------------------------------------------------------+ | 1. Who is responsible for the operation of the machine and the | | safety of the persons around the machine? Select one (1) correct | | response. | +-----------------------------------------------------------------------+ | ☐ The boss | | | | ☐ The supervisor | | | | ☐ The client | | | | ☒ The operator. | +-----------------------------------------------------------------------+ | 2. Other than the specific running of the machine what other | | training should the operator be given? Select four (4) correct | | responses. | +-----------------------------------------------------------------------+ | ☒ Manual handling of materials | | | | ☒ Changing dies | | | | ☒ Pre-start safety checks | | | | ☒ Changing punches | | | | ☐ Sheet metal casting | | | | ☐ Electrical supply maintenance and repairs. | +-----------------------------------------------------------------------+ | 3. Which of the machines below bend metal? Select two (2) correct | | responses. | +-----------------------------------------------------------------------+ | ☐ Hydraulic pan brake | | | | ☐ Cramp folder | | | | ☐ Electro-magnetic folder | | | | ☒ Bar bending machine | | | | ☒ Pipe bending machine. | +-----------------------------------------------------------------------+ +-----------------------------------------------------------------------+ | 4. What can happen to the material if the apron is not set properly? | | Select two (2) correct responses. | +-----------------------------------------------------------------------+ | ☒ The material will crack | | | | ☒ The material can split in half | | | | ☐ Nothing the material can't be folded | | | | ☐ The angles won't be accurate. | +-----------------------------------------------------------------------+ | 5. What is the difference between an electro-magnetic folder and a | | pan brake? Select one (1) correct response. | +-----------------------------------------------------------------------+ | ☒ There is no top beam to limit the depth of folds | | | | ☐ You bend up to 5 mm thick stainless steel | | | | ☐ You can only bend trays that are 150 mm deep | | | | ☐ You have to adjust the clamping pressure. | +-----------------------------------------------------------------------+ | 6. The Universal plate working machine can be used for: Select | | three (3) correct responses. | +-----------------------------------------------------------------------+ | ☒ Shearing | | | | ☒ Nibbling | | | | ☒ Punching | | | | ☐ Grinding | | | | ☐ Routing. | +-----------------------------------------------------------------------+ | 7. What are the main problems you will come across when using a | | jenny or burring machine? Select four (4) correct responses. | +-----------------------------------------------------------------------+ | ☐ Bending straight lines on 3 mm thick material | | | | ☒ Keeping the work in the correct position against the back-gauge. | | | | ☒ The correct rate of feed. | | | | ☒ The correct amount of pressure on the job | | | | ☒ The correct rate of raising the metal disc. | | | | ☐ Doming light gauge material. | +-----------------------------------------------------------------------+ | 8. What does an electronic eye beam-reflecting safety device do? | | Select one (1) correct response. | +-----------------------------------------------------------------------+ | ☐ It locates the top dead centre of the machine | | | | ☐ It helps clamp the tooling into place | | | | ☐ It adjusts the punch to its folding depth | | | | ☒ It stops the ram instantly if the beam of light is blocked. | +-----------------------------------------------------------------------+ +-----------------------------------------------------------------------+ | 9. Which is the correct pressing sequence for forming a transition | | shape? Select one (1) correct response. | +-----------------------------------------------------------------------+ | ☐ To press only on the formation lines | | | | ☒ To press from the outside to the centre of the pattern | | | | ☐ To only one quarter at a time | | | | ☐ To press from the centre to the outside of the pattern. | +-----------------------------------------------------------------------+ | 10. When should you progressively check the curvature when using a | | press brake? Select one (1) correct response. | +-----------------------------------------------------------------------+ | ☐ After every press | | | | ☐ When the job is finished | | | | ☒ After every 3 to 4 presses | | | | ☐ After every 10 presses. | +-----------------------------------------------------------------------+ | 11. Select the safe work practices involved with brake presses. | | Select six (6) correct responses. | +-----------------------------------------------------------------------+ | ☒ Check the position of the emergency stop button | | | | ☒ Be careful when lifting dies and material | | | | ☐ Wear a welding mask to protect your eyes from sparks | | | | ☒ Keep your hands clear from the press brake tooling | | | | ☒ Make sure only one person has control of the machine | | | | ☒ Check that all punch and die tooling is secured | | | | ☐ Erect safety barriers around the machine | | | | ☒ Make sure the area around the machine is neat and clean. | +-----------------------------------------------------------------------+ | 12. What plate calculations would you require before rolling a | | cylinder? Select one (1) correct response. | +-----------------------------------------------------------------------+ | ☐ The plate size | | | | ☒ Mean Circumference = 3.1412 x diameter | | | | ☐ 8-10 times the thickness of material | | | | ☐ Mean diameter = inside diameter + one thickness. | +-----------------------------------------------------------------------+ | 13. When rolling a 6 mm plate into a cylinder which diameter remains | | the same? Select one (1) correct response. | +-----------------------------------------------------------------------+ | ☒ The mean diameter | | | | ☐ The outside diameter | | | | ☐ The inside diameter | | | | ☐ The inside radius. | +-----------------------------------------------------------------------+ +-----------------------------------------------------------------------+ | 14. Which type of rolls allows for adjustment of the curve through | | the top roller? Select one (1) correct response. | +-----------------------------------------------------------------------+ | ☐ Pinch rolls | | | | ☐ Slip-rolls | | | | ☒ Pyramid rolls. | +-----------------------------------------------------------------------+ | 15. How can the plate be checked before rolling to prevent twist? | | Select two (2) correct responses. | +-----------------------------------------------------------------------+ | ☒ By aligning a plate square with a centre line drawn on the plate | | | | ☐ By guessing the back edge is parallel to the rollers | | | | ☒ By aligning a plate square 90° to the edge of the plate | | | | ☐ By eyeing up the levels of the top and bottom rollers. | +-----------------------------------------------------------------------+ | 16. What are some important steps to remember when rolling a | | cylinder? Select seven (7) correct responses. | +-----------------------------------------------------------------------+ | ☒ Check the sharpness of the bender blades | | | | ☒ Preset the ends to the desired radius | | | | ☒ Apply just enough pressure through the rollers to grip the material | | | | ☒ Increase the tension as you complete each roll | | | | ☒ Check plate remains square in the rollers | | | | ☐ Ensure the ends are connected after each roll | | | | ☒ Check the curvature after each roll | | | | ☒ Slightly over roll to allow for springback. | +-----------------------------------------------------------------------+ | 17. Select the safety requirements when operating pyramid or pinch | | rolls. Select three (3) correct responses. | +-----------------------------------------------------------------------+ | ☒ Know where the emergency stop is or any other method to stop the | | rolls quickly | | | | ☐ Run your hand over the rollers as they are moving to remove any | | foreign objects | | | | ☐ Make sure you are wearing thick heavy gloves when operating the | | rolls | | | | ☒ Check that the safety wire is in place and working if fitted to the | | machine | | | | ☒ Avoid wearing any loose clothing during rolling processes. | +-----------------------------------------------------------------------+ +-----------------------------------------------------------------------+ | 18. How can you ensure a job is made to specification? Select | | four (4) correct responses. | +-----------------------------------------------------------------------+ | ☒ Read and understand the dimensions and instructions on the drawing. | | | | ☐ Use the correct machine and tooling. | | | | ☒ Follow the correct procedures when using the machine. | | | | ☒ Check the job against inside or outside templates or over a layout. | | | | ☒ Monitor the job as it is being check progressively. | | | | ☐ Accept mistakes will be made, and these will be easily rectified at | | the end. | | | | ☐ Only use hand tools to do the job as machinery is often unreliable. | +-----------------------------------------------------------------------+ | 19. What steps need to be taken when forming material in a brake | | press? Select five (5) correct responses. | +-----------------------------------------------------------------------+ | ☒ Whether the machine has the capacity to perform the press | | | | ☒ The height of the tooling both punch and die | | | | ☒ The type of tooling to be used, knife, gooseneck etc. | | | | ☒ The throat depth on the machine | | | | ☒ Correct sequence is used to prevent fouling against the machine | | | | ☐ The voltage of the brake press | | | | ☐ The edges of the material being folded. | +-----------------------------------------------------------------------+ | 20. What safety consideration should be planned before using a break | | press? Select one (1) correct response. | +-----------------------------------------------------------------------+ | ☐ You must have protective rubber gloves | | | | ☐ No considerations need to be made | | | | ☐ Sparks can cause fire and explosions | | | | ☒ Ensure all safety guards are in working order. | +-----------------------------------------------------------------------+ +-----------------------------------------------------------------------+ | 21. In the following diagram what fault is being rectified? Select | | one (1) correct response. | | | | \\\\CCIADMFS1\\CCI-Groups\$\\ADResource Development\\1\_RD\\1. | | Development\\5\_Const\_Eng\\Manufacturing and | | Engineering\\MEM\\Units\\MEM05010\\DEV\\GD\\Complete\\Over Roll.jpg | | | | © TAFE Queensland | +-----------------------------------------------------------------------+ | ☐ Twisting | | | | ☐ Misalignment | | | | ☐ Incorrect sequence | | | | ☐ Not rolling to mean diameter | | | | ☒ Over roll. | +-----------------------------------------------------------------------+ | 22. What mechanical devices can be used to fix a job after it has | | been formed and shaped? Select four (4) correct responses. | +-----------------------------------------------------------------------+ | ☒ Jacks | | | | ☒ Sash cramps | | | | ☒ Clamps | | | | ☐ Torsion wrench | | | | ☒ Dog and wedge. | +-----------------------------------------------------------------------+ | 23. When forming or fabricating how does progressive checking help? | | Select three (3) correct responses. | +-----------------------------------------------------------------------+ | ☐ To prevent the final check from being done | | | | ☐ To prevent headaches from occurring | | | | ☒ To prevent errors | | | | ☒ To prevent twisting while pressing | | | | ☒ To prevent material being cut at the wrong size. | +-----------------------------------------------------------------------+ +-----------------------------------------------------------------------+ | 24. What checking devices and/or methods should be used when forming, | | shaping and fabricating? Select four (4) correct responses | +-----------------------------------------------------------------------+ | ☒ Tape measure | | | | ☒ Straight edge | | | | ☒ Plate, engineer's, combination square | | | | ☐ Plasma cutter | | | | ☒ Layout | | | | ☐ Press brake. | +-----------------------------------------------------------------------+ | 25. What sort of checking takes place at the end of the job? Select | | one (1) correct response. | | | |  | | | | © TAFE Queensland | +-----------------------------------------------------------------------+ | ☐ Overall dimensions of length, width or diameter | | | | ☐ Positioning and feeding requirements | | | | ☐ Alignment of seams on duct or pipe work | | | | ☐ If the workmanship meets the completion standard | | | | ☒ If the job is without twists. | +-----------------------------------------------------------------------+ | 26. What standard PPE do you need to wear when using forming | | equipment? Select three (3) correct responses. | +-----------------------------------------------------------------------+ | ☒ Safety glasses | | | | ☒ Safety boots | | | | ☒ Industrial longs | | | | ☐ Hard hat | | | | ☐ Safety harness. | +-----------------------------------------------------------------------+ +-----------------------------------------------------------------------+ | 27. What advantage does hot forming material have over cold forming | | material? Select two (2) correct responses. | +-----------------------------------------------------------------------+ | ☐ Hot forming adds strength of the metal | | | | ☐ Helps resist corrosion | | | | ☐ Assists in shrinkage | | | | ☒ Metal is formed at high speed | | | | ☒ Shaping hot metal improves resistance to cracking. | +-----------------------------------------------------------------------+ | 28. What type of rolling process is occurring in the pyramid rollers? | | Select one (1) correct response. | | | | \\\\CCIADMFS1\\CCI-Groups\$\\ADResource Development\\1\_RD\\1. | | Development\\5\_Const\_Eng\\Manufacturing and | | Engineering\\MEM\\Units\\MEM05010\\DEV\\GD\\Complete\\Skid rolling | | process.jpg | | | | © TAFE Queensland | +-----------------------------------------------------------------------+ | ☒ Skid rolling | | | | ☐ Break rolling | | | | ☐ Progressive rolling | | | | ☐ **Template rolling.** | +-----------------------------------------------------------------------+ | 29. What is the bend allowance for a 3 mm thick piece of bar formed | | at 90 degrees on a radius of 25 mm, rounded to the nearest | | millimetre? (Hint, calculate this using the length of bend | | formula). Select one (1) correct response. | +-----------------------------------------------------------------------+ | ☐ 50 mm | | | | ☐ 53 mm | | | | ☐ 47 mm | | | | ☒ 42 mm. | +-----------------------------------------------------------------------+ +-----------------------------------------------------------------------+ | 30. What length of plate is required to form into a cylinder using | | the following dimensions, rounded to the nearest millimetre? | | | |  | | | | © TAFE Queensland | +-----------------------------------------------------------------------+ | ☐ 1131 mm | | | | ☐ 1140 mm | | | | ☒ 1147 mm | | | | ☐ 1162 mm | +-----------------------------------------------------------------------+ | **End of Assessment** | +-----------------------------------------------------------------------+