Setting electro-discharge machines for production

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This standard identifies the competences you need to prepare and set up electro-discharge machines, such as spark erosion or wire erosion machines, in accordance with approved procedures. This involves selecting the appropriate workholding devices, and mounting and positioning them to the machine in the correct location for the type of operation being carried out. You will also be expected to select the appropriate electrodes or wires to use, check them for defects, and mount and secure them to the relevant parts of the machine.

You will be expected to set the electrical conditions; wire or electrode feed rate, dielectric flow rate, filtration and fume extraction systems. You must produce trial cuts, and prove the machine is working satisfactorily before declaring the installation ready for production. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.

Your responsibilities will require you to comply with organisational policy and procedures for the machine setting activities undertaken, and to report any problems with the machines, equipment or setting up activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting up procedures used. You will understand the electro-discharge machine used, and its application, and will know about the workholding devices, electrodes, relevant materials, consumables and setting up procedures, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring that the work output is to the required specification.

You will understand the safety precautions required when working with the machines and their associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

This standard does not cover CNC activities, for which other standards apply.

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1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. follow the correct specifications for the component to be produced
3. determine what has to be done and how the machine will be set to achieve this
4. mount, set and secure the required workholding devices, workpiece and cutting tools
5. set the machine tool operating parameters to achieve the component specification
6. check that all safety mechanisms are in place and that the equipment is set correctly for the required operations
7. complete the required production documentation
8. deal promptly and effectively with problems within your control and report those that cannot be solved

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1. how to work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. the hazards associated with setting electro-discharge machines , and how to minimise them and reduce any risks
3. how to start and stop the machine in normal and emergency situations
4. the importance of ensuring that the machine is isolated from the power supply before mounting electrodes, wires and workholding devices
5. the importance of ensuring that the machine is earthed before starting work
6. the importance of wearing the appropriate protective clothing (PPE) and equipment, and of keeping the work area clean and tidy
7. the basic principles of operation of the various electro-discharge machines, and typical operations that they can perform
8. how to handle and store electrodes and wires safely and correctly
9. how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to appropriate standards) in relation to work undertaken
10. how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing
11. terminology used in electro-discharge machining in relation to the activities undertaken
12. the range of eroded features that are produced on the electro-discharge machines
13. the range of workholding methods and devices that are used on electro-discharge machines
14. the methods of mounting and setting the workpiece in/on the workholding devices, and the tools and equipment that can be used
15. the different types of electrodes and wires that are used, and how they are selected, prepared and mounted to the machine tool holding devices
16. factors that determine current density, spark frequency, wire speeds and feeds, or linear feeds and speeds
17. how the various types of material will affect the feeds and speeds that can be used
18. the type of dielectrics that are used; filtration requirements; and precautions to be taken when handling and using them
19. how to set up the various machines for the particular operations being performed
20. the need to conduct trial runs, and to check that the machine is set up and running safely and correctly
21. problems that can occur with setting up the electrodes or wires, workholding devices, and machine operating parameters, and what to do if problems occur
22. the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve

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1. Carry out all of the following activities during setting up:
   1. obtain and use the appropriate documentation
   2. adhere to procedures or systems in place for risk assessment, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
   3. follow safe practice/approved setting up procedures at all times
   4. ensure that correctly adjusted machine guards are in place
   5. check that cutting tools are in a suitable condition
   6. hold components securely without distortion
   7. leave the work area and machine in a safe and appropriate condition on completion of the activities
2. Prepare one of the following types of electro-discharge machine in readiness for production:
   1. spark erosion
   2. wire erosion
3. Position and secure workpieces to machine table, to include all of the following:
   1. clamping direct to machine table
   2. fixtures
4. Select and mount electrodes for roughing and finishing, to include one of the following:
   1. plain electrodes
   2. hollow electrodes
   3. profile electrodes
   4. wire
5. Set up the machine in accordance with instructions and specifications, to include all of the following:
   1. electrical conditions
   2. alignment of electrodes
   3. wire tension
   4. linear feeds and speeds
   5. correct threading of wire through wire guides and feed mechanisms
   6. wire speeds
   7. dielectric flow rates
   8. filtration equipment
   9. ventilation and fume extraction
   10. safety mechanisms/devices
6. Set up the machine to produce internal and external profiles that include six of the following:
   1. flat faces
   2. convex forms
   3. radii/arcs
   4. square/rectangular forms
   5. square faces
   6. profile forms
   7. slots
   8. angular faces
   9. parallel faces
   10. holes
   11. threads
   12. concave forms
   13. cavities
   14. engraving
   15. other special activities
7. Machine components made from one of the following types of material:
   1. ferrous
   2. non-ferrous
8. Set the machine to produce components within all of the following quality and accuracy standards, as applicable to the operations performed:
   1. components to be free from false starts and sharp edges
   2. surface finish 32 µin or 0.8µm or 18VDI

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3

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31 Mar 2028

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Current

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Original

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Enginuity

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SEMMME3020

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Engineering, Engineering and Manufacturing Technologies, Engineering Technicians

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3113

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Engineering; manufacturing; mechanical; setting; electro-discharge machines; spark erosion; wire erosion; electrodes; tool holding devices; wire tension

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