Assignment 1: Professional Task

Rationale
This unit plan focuses on practical skills of forging and heat treating of mild steel. The unit plan aims to engage students in the task by creating projects that
students can use in their future as well as bring proven teaching strategies and effective pedagogies into the classroom. In order to do this, the lesson plan
incorporates High Impact Teaching Strategies (HITS) such as structured lessons, explicit teaching, worked examples and differentiated teaching (NSW
Education Standards Authority, 2018). These HITS teaching pedagogies have been proven to be effective teaching strategies with numerous studies
conducted into their effectiveness.

The lesson in aimed at a trade school where students are more focused on gaining skills that can be used in a future trade career. The class in made up of a
mixed ability cohort with some students needing to be challenged while most students will perform at an intermediate level. The lesson in designed to fit
into the scope and sequence towards the end of the year when students have built up competency in machine and hand tool processes. Because the school
is a trade school there is adequate equipment for students to complete the task within the time provided.

The focus of this unit plan is to give students the opportunity to develop skills, knowledge and understanding of practical skills used in the metal industry
through the use of tools and machinery to produce quality products (Board of Studies NSW, 2017). In order to develop practical skills students need to be
given explicit instructions, quality worked examples and multiple exposures to allow them to practice and develop skills. These three areas needed to
develop skills all fall within the HITS teaching Strategies (NSW Education Standards Authority, 2018) which have been proven to be effective at boosting
learning outcomes as well as engagement. This lesson plan allows the teacher to produce structured lessons focused on a single aspect of the task and also
allows students to view worked examples through demonstrations and physical examples of the process. Finally students are given multiple exposure to
new processes by first viewing demonstrations then by attempting the process themselves and by viewing other students attempting the process (when
they are working in groups). Students are also given multiple exposures of other processes learned in other tasks through reparative processes learned
previously, for example lathe operations.

1 Stage 5 / Year 10 | Core Module: Metal 1

 Assignment 1: Professional Task

Course: Industrial Technology - Metal Stage/Year: Stage 5/Year 9 Module: Core Module: Metal 1 Duration: 5 Weeks

Overview/ purpose of the unit

In this unit, students will learn about the effect of work procedures and how different processes need to be completed before others. Students will also
learn how to shape materials using the process of forging. Students also learn how to change the properties of materials through processes of annealing
and tempering. In this project, students also get to apply previously learned skills to create a unique design on their chisel.

Outcomes
› identifies, assesses, applies and manages the risks and WHS issues associated with the use of a range of tools, equipment, materials, processes and
technologies IND5-1
› applies design principles in the modification, development and production of projects IND5-2
› identifies, selects and competently uses a range of hand and machine tools, equipment and processes to produce quality practical projects IND5-3
› selects, interprets and applies a range of suitable communication techniques in the development, planning, production and presentation of ideas and
projects IND5-5
› applies and transfers skills, processes and materials to a variety of contexts and projects IND5-7
› evaluates products in terms of functional, economic, aesthetic and environmental qualities and quality of construction IND5-8

Related Life Skills outcomes: INDLS-1, INDLS-2, INDLS-3, INDLS-5, INDLS-7, INDLS-8,

Learning Across the curriculum Areas

Information and communication technology capability Personal and social capability
Literacy Work and enterprise
Numeracy

Assessment
Portfolio and evaluation of final product produced, including a practical demonstration to determine tempering effectiveness.

2 Stage 5 / Year 10 | Core Module: Metal 1

 Assignment 1: Professional Task

Extending students.
For students that need to be given more challenging work, they can also produce a welding chisel. The students will focus on forging a pick with one flat end
and a rounded end with a forged handle attached in the middle. This provides a challenge as forging a rounded pick is much harder than a flat chisel.
Additionally heat treating and tempering both ends is difficult and requires an advance level of skill.

Learning Intentions:
In this unit, the students will learn more about the effect of work procedures and how different processes need to be completed before others. Students
also learn about heat treating and how it can be used to shape metal and also give it desired properties.

3 Stage 5 / Year 10 | Core Module: Metal 1


Outcomes
› identifies, assesses, applies and
manages the risks and WHS
issues associated with the use
of a range of tools, equipment,
materials, processes and
technologies IND5-1
Task 1 – WHS and Risk Management
4 Stage 5 / Year 10 | Core Module: Metal 1
Assignment 1: Professional Task
Cold Chisel
Content
WHS and risk management
Students:
 demonstrate safe workshop practices and
procedures, for example:
– follow workshop signage instructions
(1a)
– return lengths of steel to the racks after
cutting (1b)
– wear gloves when heating metal (1c)
– work collaboratively (1d)
 safely use and maintain hand, power and
machine tools (2)
 select and use personal protective
equipment (PPE) when working with tools,
materials and machines, for example:
– wear appropriate footwear (3a)
– wear eye protection, eg safety glasses
when drilling (3b)
– wear protective clothing (3c)
 apply the principles of risk management, for
example:
– identify a particular risk and implement
risk-reduction procedures (4)
 describe elementary first aid procedures, for
example:
– outline the procedure to follow after a
particular incident, eg burns, cuts (5)
Teaching and Learning activities
Throughout the lesson plan WHS and risk
management will be an ongoing and continuous
aspect of practical work. These points will be initially
revised at the beginning of the project and reiterated
at the beginning of each task or as the WHS issue
becomes relevant or as needed to ensure the safety
of students and staff.
Note: Throughout the lesson plan numbers in
brackets will refer the specific WHS and risk
management issue that needs to be addressed.
Teacher is to lead a review of WHS and Risk
management issues that will be faced during this
task. The following issues are to be discussed:
1. Workshop signage
2. Material handling
3. Correct PPE usage
4. Machine & power tool safety
5. Hand tool safety
6. Risk identification
7. Proper first aid procedures
WHS 1a, 1d, 2, 3a-c, 4 and 5
 Assignment 1: Professional Task

› applies design principles in the Design

Teacher is to introduce the task students will
modification, development and  use and/or modify existing designs when undertake over the next 4 weeks, making a cold
production of projects IND5-2 completing projects chisel.
Task 2 – Task introduction

 apply project management techniques and

Teacher is to hand out and describe the work
follow a planned sequence through to
involved in finishing the portfolio over the next 4
project completion
weeks.

Resources
Portfolio of work template both digital and hard copy
for students to use.

5 Stage 5 / Year 10 | Core Module: Metal 1

 Assignment 1: Professional Task

› applies design principles in the
modification, development and
production of projects IND5-2
› selects, interprets and applies a
range of suitable
communication techniques in
the development, planning,
production and presentation of
ideas and projects IND5-5
› evaluates products in terms of
functional, economic, aesthetic
Task 3 - portfolio
 read and interpret plans and/or materials
lists to prepare materials for the completion
of projects, for example:
○ sheet metal developments
 develop design and production folios using
appropriate ICT, for example:
○ CAD
○ simulations
○ spreadsheets
 prepare design and production folios to
describe the management and processes
Students Tasks in portfolio
 Develop material list for project
 Develop design for unique handle including;
o CAD drawing of handle including
required dimensions
o Planned sequence of work to
complete handle
 Develop a planned sequence of work for the
cold Chesil project.
 Detail process used during the task,

and environmental qualities undertaken in the production of practical including;

and quality of construction projects, for example: o Cutting
IND5-8 ○ equipment used o Forging
 identification and use of materials o Shaping
 apply project management techniques and o Heat treating
follow a planned sequence through to o Sharpening
project completion o Finishing
 evaluate the impact of design and work o Processes unique to their handle
practices/processes on the quality of finished design
projects  Images of their project as they are producing
it.
 Self-evaluation of their work and the
processes used to create it and how these
effected the quality.

6 Stage 5 / Year 10 | Core Module: Metal 1


› applies design principles in the
modification, development and
production of projects IND5-2
› applies and transfers skills,
processes and materials to a
Task 4 – process and steps
variety of contexts and projects
IND5-7
› identifies, assesses, applies and
manages the risks and WHS
issues associated with the use
of a range of tools, equipment,
Task 5 - Cutting
materials, processes and
technologies IND5-1
› identifies, selects and
competently uses a range of
hand and machine tools,
equipment and processes to
produce quality practical
projects IND5-3
7 Stage 5 / Year 10 | Core Module: Metal 1
Assignment 1: Professional Task
 apply project management techniques and
follow a planned sequence through to
project completion
 evaluate the impact of design and work
practices/processes on the quality of finished
projects
 select, use and maintain appropriate
machine and power tools for metal projects,
for example:
– cutting stock using a cold saw
Teacher is to guide the students through producing a
workshop plan to create the cold chisel. This will
include deciding on the processes that will be used
and the order that they will be conducted.
Students will develop the workshop plan for the cold
chisel. This can be done using computer software or
by hand. The completed task needs to be inserted
into their portfolios.
Students will assess the impact of each process
Teacher is to check that each student has a working
and feasible plan before work can commence.
Resources
Computers
List of processes needed to complete task.
Teacher is to describe the use of a cold saw and how
to correctly use and set up the machine.
Students are to cut their own material out on the
cold saw.
WHS 1a, 1b, 2, 3a-c, 4 and 5

› applies design principles in the
modification, development and
production of projects IND5-2
› selects, interprets and applies a
range of suitable
communication techniques in
Task 6 - Unique Design
the development, planning,
production and presentation of
ideas and projects IND5-5
› applies and transfers skills,
processes and materials to a
variety of contexts and projects
IND5-7
8 Stage 5 / Year 10 | Core Module: Metal 1
Assignment 1: Professional Task
 use and/or modify existing designs when
completing projects
Students are to design their own unique handle for
their cold chisel. The design must be able to be
created using;
 Lathe,
 Milling machine, or
 Hand tools
A drawing of the design along with dimensions needs
to be produced either by producing a CAD model of
the design or by creating a orthogonal drawing by
hand. (student may be given the original chisel part
file in order for them to create a 3D CAD model)
Students are to outline the steps and processes
needed to complete design.
Teacher is to check over students’ designs and
processes to ensure that the design is achievable.
 Assignment 1: Professional Task
 describe the processes and materials used in
the production of steel, for example:
– alloying elements, eg carbon in steel
– blast furnace
Task 7 - Forging theory
– electric arc furnace
9 Stage 5 / Year 10 | Core Module: Metal 1
Watch You Tube video on forging and heat treatment
https://www.youtube.com/watch?v=6jQ4y0LK1kY
Teacher is to describe the forging process and the
different types of forging;
 Impression Die Forging.
 Cold Forging.
 Open Die Forging.
 Seamless Rolled Ring Forging.
Teacher is to describe what materials forging can be
used on, focusing on steel and the content of carbon.
Teacher is to also describe the procedure used when
forging by hand, paying particular attention on the
colours of the metal during the process.

› identifies, assesses, applies and
manages the risks and WHS
issues associated with the use
of a range of tools, equipment,
materials, processes and
technologies IND5-1
› identifies, selects and
Task 8 - Forging chisel
competently uses a range of
hand and machine tools,
equipment and processes to
produce quality practical
projects IND5-3
10 Stage 5 / Year 10 | Core Module: Metal 1
Assignment 1: Professional Task
 apply techniques and equipment for the
cutting, shaping and forming of angle, rod
and flat bar
Teacher is to describe the process needed to forge
the cold chisel. This includes:
 Safe use of oxy-acetylene,
 Start up and close down procedures for oxy-
acetylene bottles,
 The type of fitting used on the oxy-acetylene
bottles,
 Safe handling of hot materials
 Forging procedure, heating, shaping,
reteating.
 Cooling process,
 WHS and risk management issues,
 First aid,
 What the finished product will look like.
Students are to work in groups of 3 to 4 around a
furnace to heat and form their cold chisel.
WHS 1a, 1c, 1d, 3a-c, 4 and 5

› identifies, assesses, applies and
manages the risks and WHS
issues associated with the use
Task 9 - shaping chisel
of a range of tools, equipment,
materials, processes and
technologies IND5-1
› identifies, selects and
competently uses a range of
hand and machine tools,
equipment and processes to
produce quality practical
projects IND5-3
› identifies, assesses, applies and
manages the risks and WHS
issues associated with the use
Task 10 - Creating unique Handle
of a range of tools, equipment,
materials, processes and
technologies IND5-1
› identifies, selects and
competently uses a range of
hand and machine tools,
equipment and processes to
produce quality practical
projects IND5-3
› applies and transfers skills,
processes and materials to a
variety of contexts and projects
IND5-7
11 Stage 5 / Year 10 | Core Module: Metal 1
Assignment 1: Professional Task
 apply techniques and equipment for the
cutting, shaping and forming of angle, rod
and flat bar
 use and adjust a range of hand tools in the
production of practical projects, for example:
– marking out, eg scriber, rule, try square,
jenny calipers
– cutting and shaping, eg hacksaw, bench
shears, files
– joining, eg soldering iron, rivet gun
 perform metal lathe operations, for example:
– drilling
– facing
– knurling
– parallel turning
Teacher is to instruct students in the correct way of
shaping the cold chisel using files.
Teacher is to instruct students on what the final
product should look like.
Students are to finish shaping the ends of their cold
chisel using files.
WHS 1a, 1d, 2, 3a-c, 4 and 5
Students are to create their unique handle on their
cold chisel. This is to be done using the design and
process developed in Task 6. This is to be created
using hand tools, lathes or milling machines.
Ideas for handles:
 creating initials in Morse code,
 creating a unique pattern,
 Milling flats on to the round bar,
Teacher is to assist students in creating their designs.
WHS 1a, 1d, 2, 3a-c, 4 and 5
 Assignment 1: Professional Task

› identifies, assesses, applies and
Task 11 - Preparing Chisel for Heat manages the risks and WHS
issues associated with the use
of a range of tools, equipment,
materials, processes and
Treating
 apply techniques and equipment for the
cutting, shaping and forming of angle, rod
and flat bar
 prepare and finish metal surfaces, for
example:
Teacher is to show students how to sharpen their
cold chisel on the disk grinder. Also the students will
be shown how to prepare their chisel for heat
treating.

technologies IND5-1
› identifies, selects and
competently uses a range of
hand and machine tools,
equipment and processes to
produce quality practical
projects IND5-3
– buffing and polishing Students are to sharpen and polish their cold chisel
– enamelling ready to heat treat the tip of the chisel.
– painting This is to be done using wet and dry, emery cloth and
– plastic coating files.
This is needed so that the colour change of the
material can be seen.

 modify the properties of metals through You Tube Video on tempering and hardening
Task 12 -

Treating

heat-treatment processes, for example: https://www.youtube.com/watch?v=llRiYk6teSc

Theory
Heat

– annealing
– hardening Teacher is to describe the process that will be used
to anneal and harden the cold chisel.

12 Stage 5 / Year 10 | Core Module: Metal 1


› identifies, assesses, applies and
manages the risks and WHS
issues associated with the use
of a range of tools, equipment,
materials, processes and
technologies IND5-1
› identifies, selects and
Task 13 - Heat treating
competently uses a range of
hand and machine tools,
equipment and processes to
produce quality practical
projects IND5-3
› identifies, assesses, applies and
manages the risks and WHS
issues associated with the use
of a range of tools, equipment,
Task 14 - Finishing
materials, processes and
technologies IND5-1
› identifies, selects and
competently uses a range of
hand and machine tools,
equipment and processes to
produce quality practical
projects IND5-3
13 Stage 5 / Year 10 | Core Module: Metal 1
Assignment 1: Professional Task
 modify the properties of metals through Teacher is to demonstrate the process that will be
heat-treatment processes, for example: used to harden the cold chisel, this includes;
– annealing  Annealing the material - consists of heating
– hardening and cooling slowly to remove any impurities
created during forging.
 Hardening the material - consists of heating
the forged end of the bar to red hot and
quenching in oil to create a hard point.
 Tempering the material - consists of heating
the material up until is a uniform straw
colour and quenching. This allow as for a
hard but not brittle tip.
Result is a sharp strong tip that can chisel untreated
mild steel without blunting.
Students are to apply this process to their cold
chisels. And test the result of their heat-treatment
processes.
WHS 1a, 1c, 1d, 3a-c, 4 and 5
 prepare and finish metal surfaces, for Students are to finish their chisels by polishing,
example: painting or other desired finishing process.
– buffing and polishing
– enamelling
– painting
– plastic coating
 Assignment 1: Professional Task

› selects, interprets and applies a  evaluate the impact of design and work Students are to finish their portfolios and include an
Task 15 - portfolio end task range of suitable practices/processes on the quality of evaluation of their project. This will then be handed
communication techniques in finished projects in for marking.
the development, planning,
production and presentation of
ideas and projects IND5-5
› evaluates products in terms of
functional, economic, aesthetic
and environmental qualities
and quality of construction
IND5-8

14 Stage 5 / Year 10 | Core Module: Metal 1

 Assignment 1: Professional Task
Program Evaluations:
Teacher Evaluation

Student Evaluation

References
NSW Education Standards Authority. (2018). NSW Syllabus for the Australian Curriculum: Industrial Technology Year 7-10 Syllabus

Department of education and training. (2017). High Impact Teaching Strategies: Excellence in Teaching and Learning. Retrieved from

https://www.education.vic.gov.au/Documents/school/teachers/support/highimpactteachstrat.pdf

15 Stage 5 / Year 10 | Core Module: Metal 1

 Assignment 1: Professional Task

Chisel portfolio

Student Name: ______________________

Class: ______________

16 Stage 5 / Year 10 | Core Module: Metal 1

 Assignment 1: Professional Task

Constance page
WHS Issues and requirements
List any Work Health and Safety (WHS) or risk management issues that may arise during the course
of the project and what can be done to reduce or remove their safety in the workshop.

WHS or risk management issues Mitigation strategy

17 Stage 5 / Year 10 | Core Module: Metal 1

 Assignment 1: Professional Task

Basic chisel design

Drawing of Cold chisel is to be inserted.

18 Stage 5 / Year 10 | Core Module: Metal 1

 Assignment 1: Professional Task

Cutting list
Students are to select the length of their cold chisel, max length = 200mm minimum length =
100mm. The diameter of the bar can also be selected by the

Material Bar diameter Length Profile

(Max=20mm, min=10mm) (Max=200mm, min=100mm) (Round, square or Hexagonal bar)

Project management
In this project planning section you are to develop a planned sequence of operations that will be
needed to complete your cold chisel. This is the initial plan and this is allowed to change throughout
the initial manufacturing process. If this occurs changes must be made to the plan and highlighted in
Blue. Please include any photos you think are relevant.

Note: one operation must be “create unique handle”

Operation Description Photos

19 Stage 5 / Year 10 | Core Module: Metal 1

 Assignment 1: Professional Task

Unique handle design

You are to insert a completed orthogonal drawing of your unique handle. The drawing must have,
front top and side view, fully dimensioned handle and title block.

Project management – unique handle

In this project planning section you are to develop a planned sequence of operations that will be
needed to complete your unique handle on your cold chisel. This is the initial plan and this is
allowed to change throughout the initial manufacturing process. If this occurs changes must be
made to the plan and highlighted in Blue. Please include any photos you think are relevant.

Operation Description Photos

20 Stage 5 / Year 10 | Core Module: Metal 1

 Assignment 1: Professional Task

Machinery and Tools

In this section you are to identify the tools and machinery required to produce the cold chisel.
Photos of machinery and equipment are acceptable descriptions. Best photos are of set up
equipment

Machinery or tool Photo or description

21 Stage 5 / Year 10 | Core Module: Metal 1

 Assignment 1: Professional Task

Forging process
Please identify and describe the process of forging used to create the cold chisel. Photos can be used
to assist with description.

1.
____________________________________________________
2.
____________________________________________________
3.
____________________________________________________
4.
____________________________________________________
5.
____________________________________________________
6.
____________________________________________________
7.
____________________________________________________

22 Stage 5 / Year 10 | Core Module: Metal 1

 Assignment 1: Professional Task

Annealing, Hardening and Tempering process

Please identify and describe the process of forging used to create the cold chisel. Photos can be used
to assist with description.

1.
____________________________________________________
2.
____________________________________________________
3.
____________________________________________________
4.
____________________________________________________
5.
____________________________________________________
6.
____________________________________________________
7.
____________________________________________________

23 Stage 5 / Year 10 | Core Module: Metal 1

 Assignment 1: Professional Task

Project evaluation
Write down some of the pros and cons of this project. Include what worked well from a production
prospective and for the creation of your unique han

24 Stage 5 / Year 10 | Core Module: Metal 1