CNC Milling

Technical Description 2022

─
Adam Youens
WorldSkills UK
Enquiries: [email protected]
[email protected]
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We thank all the amazing sponsors that make this competition possible:
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Introduction
WorldSkills UK is an annual skills competition designed to promote standards and skills
across a wide range of industries, developing competence into excellence.

The CNC Milling competition sees talented engineers test their expertise on a series of
challenging practical tests in a bid to be named WorldSkills UK National Champion.

WorldSkills UK can bring invaluable benefits to students, colleges, and employers.

Competitors can gain recognition for exceptional skills, injecting dynamism, and
excitement into training.

Employers can enhance their business reputation and improve the skills of their workforce.

The aim of this technical manual is to help competitors prepare for the CNC Milling
competition from registration, through passive to qualifying and culmination at the
national level.

The guide contains general advice, technical tips and an in-depth overview of the
competition structure and its content.

CNC Milling is a significant sector within the engineering industry, encompassing a wide
range of skills, standards, and ideas. This guide will provide you with a clear path to follow,
from initial registration to the National finals and beyond.
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Role Overview
The CNC machinist / Technician role can cover a wide range of skills such as machine setting
and operating, CNC programming and editing and the use of CAD/CAM software to generate
efficient machining strategies that can be output as CNC programs.

They are expected to safely prove out CNC programs while ensuring that the production
process is also optimised. Completed components must be checked and inspected against
tight tolerances and quality standards

Key attributes required by all CNC technicians wherever they work are efficient work
organisation, self-management, communication, interpersonal skills and problem-solving.

They must have the ability to work safely and rigorously adhere to regulations,
manufacturer’s instructions, and organisational requirements. These universal traits are
the benchmark of an outstanding CNC technician.
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Resources
For information and resources, including how to register, competition rules, and the steps
to competing, visit:

CNC Milling Google classroom

Mastercam home learning edition

Competition Page

WorldSkills competition Rules

Careers Page

Core competencies
Projects will be designed to test competitors technical ability to;

● Follow relevant safety practises

● Read engineering drawings
● Understand tolerances
● Create wireframe geometry
● Create and modify solid models
● Program CNC toolpaths from solid models and wireframe
● Produce CNC programs
● Set a machine vice
● Set tool information on machine
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● Calculate speeds and feeds

● Run CNC programs safely
● Accurately measure and adjust tool information
● Compete under time pressure
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Competition Structure

Registration

Once you have completed your registration (and accepted all terms and conditions) you
will receive email confirmation and will be sent a link to join a Google Classroom here you
will find further details about the competition and be asked to complete the Passive test
online

Prospective students should try to familiarise themselves with working under competition-
style activities, for example, have a fellow student judge a completed work task during a
timed practical session at college/training provider.

Passive Stage

The passive test consists of multiple choice type questions.

It covers a range of relevant topics and is aimed at challenging and assessing your
knowledge of general and specific topics of CNC machining and Engineering

When all registered entrants have completed the passive test, you will be notified if you
have scored high enough to progress to the National Qualifying round.

National Qualifiers

Ensure you are ready to compete in your National Qualifier by reading and understanding
the project brief, core competencies. This outlines the tasks you will be expected to carry
out.

Ask your lecturer/employer for help in any areas where you feel you may have any
knowledge gaps and work to improve/gain the necessary skills.

The Qualifying task will be to program and produce a component to the correct quality
standards on a CNC Milling machine within a specified time limit. A 2D engineering
drawing will be provided

Any CAD/CAM system may be used to create the program. The finished test project
component must be sent for judging with a copy of the CAD/CAM file and output CNC
code.
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The test project should be sent to:

Adam Youens
Coleg Cambria
Engineering Technology Centre
Bersham Road
Wrexham, LL13 7UH

WorldSkills UK Pre-National training

As part of the invitation to compete at the National Finals, WorldSkills CNC Turning invites
all competitors to a training event beforehand. This is an excellent opportunity for all
competitors to boost their confidence using/familiarising the equipment in a safe
environment while replicating the competition project and expectations.

Training dates are yet to be released but expected in September/October 2022 at Coleg
Cambria, Wrexham.

WorldSkills UK National Final

The highest scoring competitors across the National Qualifier will be invited to compete at
the finals.

The competition task will be to program and produce a component to the correct quality
standards on a CNC Lathe within a specified time limit. A 2D engineering drawing will be
provided and in some cases a 3D CAD model

Ensure you are ready to compete in your WorldSkills UK Live final by reading and
understanding the project brief, core competencies. This outlines the type of tasks you will
be expected to carry out.

Ask your lecturer/employer for help in any areas where you feel you may have any
knowledge gaps and work to improve/gain the necessary skills.

Self-directed training
All competitors will need to practice to make it to the National finals. Dedication is key to
confident performance in a competition.
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Project overview
While the project drawings and models can vary greatly within CNC milling, we have
reduced the number of features to test core skills while keeping cost manageable for
organisers and entrants. So only the following features will be included

Included features Optional features

-Profile contours -Reamed holes

-Pockets -Tapped holes
-Slots, open or closed -Bosses
-Drilled holes -Bores
-Chamfers -Engraving
-Radii

Passive Stage
A simple passive stage has been designed to test individuals' knowledge. This will consist of
a short quiz on machines and machine operation, programming, health and safety, and
measuring. As well as this there are a few questions on WorldSkills competitions. The
passive Stage Quiz can be found on the Google classroom linked above.
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Project example: National qualifiers

Design specification

Material Aluminium 100x100x50mm

Time 7h

Additional data ● 2D drawing with 3D shaded view; all dimensions included

● Work on 2 or 3 faces
● Minimum size for a finished part is not smaller than 50x50x30mm
● Will be possible with minimal tooling 6mm and 12mm end mills
with 9.8mm drilling
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Project example: National finals

Design specification

Material Aluminium 100x100x20mm

Brass 80x80x20mm

Time 6h (2.5h programming)

Additional data ● 2D drawing with 3D shaded view; critical dimensions only

● 3D step file or Mastercam file
● Work on 2 or 3 faces
● Minimum size for a finished part is not smaller than 30x30x10mm
● Will use any combination of tooling from the equipment list
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Marking scheme
The marking scheme is designed to fairly compare every competitor’s work. Marking is split
between measurement and judgement aspects.

Measurement
Any dimension on the drawing can be a measurement mark. The value of a given dimension
is decided by its tolerance, which are split into:

● Main dimensions (±0.005mm to ±0.02mm)

● Secondary dimensions (±0.04mm)
● General tolerance (±0.1mm)
● Surface finish (0.8Ra to 1.6Ra)

All projects will be supplied with a mark summary form. The mark summary form will show
only the number of marks assigned to each aspect, not the breakdown of marks (e.g., main
dimensions: 40 marks maximum).

All marks for measurement criteria are “all or nothing”, e.g., if a dimension is specified at
40±0.04, full marks will be awarded from 39.960mm to 40.040mm. Anything outside of this
will be awarded zero marks.

Judgement
Judgement marks are more subjective, for aspects such as:

● False cuts (collisions)

● Vibration
● Scratches
● Machine deburring
● Hand deburring

Judges will work to a judgement handbook with examples of each criterion. Each judge will
reveal a value from zero to three, and an average will be taken. For example, if all judges
assess the machine deburring as a two overall, the competitor will receive 66% of the
possible marks. Judgement marking accounts for only 10% of the overall score.
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Edges should be broken on machine where possible:

Avoid the following:

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Equipment
During training and delivery of the National finals, lots of tooling and equipment will be
provided by WorldSkills UK and various competition sponsors. All provided equipment to
produce the test project is specified here:

Measuring (Mitutoyo)
TOOL PRODUCT CODE

Gauge block set 47 pieces 516-962-11

Digimatic height gauge 300mm min resolution 1/1000mm 570-312

Digital depth micrometer 0-6" 329-350-30

Digimatic calipers 0-150mm 500-196-30

Dial test indicator 0.001 1mm 513-908-10E

Magnetic dial indicator stand 7010SN

Outside micrometer 0-25mm 293-344-30

Outside micrometer 25-50mm 293-345-30

Outside micrometer 50-75mm 293-346-30

Outside micrometer 75-100mm 293-347-30

Telescopic gauge set 8-150mm (6pcs) 155-905

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Inside micrometer 25-50mm 141-101

Inside micrometer 50-75mm 141-205

Borematic set 16-20mm Dia 468-265

Borematic set 20-25mm Dia 468-266

Set of feeler gauges 0.05-1mm 184-304s

Digital disc micrometer IP65 0-1" 323-350-30

Radius gauge sets to measure 1-6mm internal 186-902

Radius gauge sets to measure 3-15mm external 186-106

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Setting
TOOL PRODUCT CODE

4ton hydraulic vice+clamps 148545

Tool boy

Hide/copper mallet

26mm pull studs

29mm pull studs

50mm soft set 2397-502A

50mm Insize zero setter 6550-50A

Parallels (Link for reference only)

45mm thread gauge 1.5pitch 6g

10H7 plug gauge

M6 thread gauge 1pitch 6H

Radius gauge set

Nogi de-burr

Nogi tips

Needle files

Black marker pens

Cutting (Sandvik Coromant)

TOOL PRODUCT CODE

6mm endmill 2P160-0600-NA H10F

10mm endmill 2P232-1000-NA H10F

5mm drill 460.1-0500-025A1-XM GC34

9.8mm drill 460.1-0980-029A1-XM GC34

M6 tap E207M6

10mm reamer 435.T-1000-A1-XF H10F

6mm engraver N/A

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Machine
DMG Mori CMX800 with Siemens control

Software
CAD/CAM
Mastercam home learning edition
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Training

Self-directed training
All competitors will need to practice to make it to the National finals. Dedication is key to
confident performance in a competition.

National finals

What to expect
Employers can enter the competition floor with the permission of the competition manager;
they can take sponsorship photos or gain a better understanding of the competition itself.
Competitors are expected to wear the appropriate H&S equipment (e.g., safety boots,
glasses) as well as a company work top and trousers while competing.

The competition stand will be prepared with all the equipment necessary to compete. Each
competitor will have a computer they can password protect, as well as a USB to back up files.
There will be one set of measuring equipment and cutting tools per machine, which will be
checked and cleaned between each competitor’s shift.

An example timetable:
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Beyond the National finals

Looking beyond the National finals, there are a host of opportunities for competitors. Age-
eligible competitors who show the highest skills, passion, and drive to compete will be invited
to train for the EuroSkills and WorldSkills international competitions.

Those who are not eligible for international competitions may join the Champions
programme, which allows continued involvement, including the opportunity to work with
WorldSkills UK and visit schools, colleges, and events to inspire the next generations.

Alternatively, if training is of interest to you, you could consider supporting WorldSkills UK

with organising and training, and even helping to run the National finals.

Get inspired and become a part of Team UK today!

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