CNC ELECTRIC DISCHARGE MACHINE (EDM)-WIRE CUT OPERATION NC III COURSE

TESDA TRAINING REGULATIONS FOR CNC ELECTRIC DISCHARGE MACHINE (EDM)-WIRE CUT OPERATION NC III

The TESDA Course in CNC Electric Discharge Machine (EDM)-Wire Cut Operation NC III consists of competencies that a person must achieve to write CNC ED- wire cut program, set-up CNC EDM-wire cut, cutting wire and workpiece, perform CNC EDM-wire cut operation and post CNC EDM-wire cut operations.

A student who has achieved this TESDA Course in CNC ELECTRIC DISCHARGE MACHINE (EDM)-WIRE CUT OPERATION NC III is competent to be:

• CNC EDM Wire Cut Operator
• CNC EDM Wire Cut Programmer

TRAINEE ENTRY REQUIREMENTS

This section specifies the qualifications of trainees and their educational attainment. Other requirements like health and physical requirements are also stated. Passing entry written entrance examinations may also be indicated if necessary.

• Must have completed the 10-year basic education or an Alternative Learning System (ALS) Certificate of Completion with grade 10 equivalent holder
• Must have competence in CNC Programming acquired through training or work experience or certification
• Can communicate orally and or in writing
• Can perform basic mathematical computation

CNC ELECTRIC DISCHARGE MACHINE (EDM)-WIRE CUT OPERATION NC III COURSE MODULE

Course Title: CNC ELECTRIC DISCHARGE MACHINE (EDM)-WIRE CUT OPERATION
Level: NC III
Nominal Training Duration :

(Basic Competency) 40 hours
(Common Competency) 120 hours
(Core Competency) 136 hours

TOTAL DURATION: 296 Hours

This course is designed to enhance the knowledge, skill and attitudes in CNC ELECTRIC DISCHARGE MACHINE (EDM) – WIRE CUT OPERATION NC III in accordance with industry standards. This covers the competencies required to write CNC EDM-wire cut program, set-up machine, cutting wire and workpiece and perform CNC EDM -wire cutting and perform post-CNC EDM-wire cut operation.

Upon completion of the course, the learners are expected to demonstrate the above-mentioned competencies to be employed. To obtain this, all units prescribed for this qualification must be achieve.

COMPETENCIES REQUIRED IN CNC ELECTRIC DISCHARGE MACHINE (EDM)-WIRE CUT OPERATION NC III

This units of competency comprising this qualification include Basic, Common and Core Competencies.

To obtain this TESDA Course in CNC ELECTRIC DISCHARGE MACHINE (EDM)-WIRE CUT OPERATION NC III, all units prescribed below for this qualification must be achieved.

These units of competency comprising this qualification include the following:

UNIT CODE	CORE COMPETENCIES (136 hours)
MEE821317	Write CNC Electric Discharge Machine (EDM)- wire cut program
MEE821318	Set-up CNC Electric Discharge Machine (EDM)- wire cut , cutting wire and workpiece
MEE821319	Perform CNC Electric Discharge Machine (EDM)-wire cut operations
MEE821320	Perform post CNC Electric Discharge Machine (EDM)- wire cut operations
UNIT CODE	COMMON COMPETENCIES (120 hours)
MEE722201	Apply safety practices
MEE722202	Interpret working drawings and sketches
MEE722203	Select/ cut workshop materials
MEE722204	Perform shop computations (Basic)
MEE722205	Measure workpiece (Basic)
MEE722206	Perform routine housekeeping
MEE722207	Perform shop computations (Intermediate)
MEE722208	Measure workpiece using angular measuring instruments
MEE722210	Measure workpiece using gages and surface texture comparator
MEE722211	Perform preventive and corrective maintenance
ICT311201	Operate a personal computer
UNIT CODE	BASIC COMPETENCIES (40 hours)
400311319	Lead workplace communication
400311320	Lead small teams
400311321	Apply critical thinking and problem-solving techniques in the workplace
400311322	Work in a diverse environment
400311323	Propose methods of applying learning and innovation in the organization
400311324	Use information systematically
400311325	Evaluate occupational safety and health work practices
400311326	Evaluate environmental work practices
400311327	Facilitate entrepreneurial skills for micro-small-medium enterprises (MSMEs)

These guidelines are set to provide the Technical Vocational Education and Training (TVET) providers with information and other important requirements to consider when designing training programs for CNC ELECTRIC DISCHARGE MACHINE (EDM)-WIRE CUT OPERATION NC III.

CORE COMPETENCIES

UNIT OF COMPETENCY : WRITE CNC ELECTRIC DISCHARGE MACHINE (EDM)-WIRE CUT PROGRAM
UNIT CODE : MEE 821317

This unit covers the knowledge and skills required to write programs for CNC EDM wire cut.

1. Confirm job requirement
   • Drawing is interpreted and confirmed with the supervisor
   • Cutting wire is selected according to the job requirement
   • Workpiece is received and inspected based on the drawing
   • Safety practices are applied according to OSHS
2. Write CNC EDM wire cut program
   • Desk top computer is used according to standard operating procedures.
   • Sequence of wire cut operation is determined according to industry standard procedures
   • Drawing is generated using software according to industry standard procedures
   • Wire path programs are written according to software annual
   • Data of wire parameter is filled up according to standard operating procedures
   • CAD drawing is saved to designated folder according to industry procedures
   • Safety practices are applied according to OSHS
3. Edit CNC EDM wire cut programs
   • (CAD) Program is simulated and edited according to standard operating procedures.
   • Program is saved to designated folder according to industry procedures
   • Program is downloaded/ inputted to the machine using appropriate devices (CF card) according to industry procedures
   • Safety practices are applied according to OSHS

UNIT OF COMPETENCY : SET-UP CNC ELECTRIC DISCHARGE MACHINE (EDM)-WIRE CUT, CUTTING WIRE AND WORKPIECE
UNIT CODE : MEE 821318

This unit covers the knowledge and skills required to set-up CNC EDM wire cut, cutting wire, workpiece and dry-run program.

1. Prepare machine
   • EDM wire cut type and capacity is selected according to job requirement
   • Oil, grease and deionized water is checked according to manufacturer’s specification.
   • Electrical settings and parameters are checked according to manufacturer’s specification
   • Air and hydraulic pressure is checked according to manufacturer’s specification.
   • Work holding and clamping devices are mounted according to standard operating procedures.
   • Perpendicularity and verticality of machine axes is checked using precision instruments according to operating manual
   • Safety practices are applied following OSHS
2. Set-up cutting wire
   • Check verticality of upper and lower guide
   • Nozzles are selected according to cutting wire diameter
   • Nozzles are mounted according to industry procedure
   • Cutting wire is mounted according to job requirement.
   • Safety practices are applied following OSHS
3. Set-up workpiece
   • Workpiece is mounted on clamping device according to industry practices
   • Workpiece is checked for perpendicularity and verticality according to industry standard procedures
   • Workpiece is centered and zero reference point is set according to industry standard procedures
   • Safety practices are applied following OSHS
4. Dry-run program
   • Dry-run is performed in accordance with the desired tool path movement.
   • Dry-run is monitored and parameters are adjusted according to standard industry procedure.
   • Safety practices are applied following OSHS

UNIT OF COMPETENCY : PERFORM CNC ELECTRIC DISCHARGE MACHINE (EDM) -WIRE CUT OPERATIONS
UNIT CODE : MEE 821319

This unit covers the knowledge and skills required to operate CNC EDM wire cut operations such as slots and keyways, profiles like circular, rectangular, vees, and external / internal radii and tapering.

1. Operate EDM wire cut
   • Submerge workpiece with deionized water according to EDM operating manual
   • Dry run is conducted and parameter adjustments are made if required according to EDM operating manual
   • EDM is operated to meet dimensions and surface texture according to job requirements
   • EDM accessories are used according to job requirements
   • Safety practices are applied following OSHS
2. Monitor performance of machine and cutting wire
   • Performance of the machine and cutting wire are monitored in the power control unit based on the accepted industry standards
   • Deionized water level is maintained according to machine operating manual
   • Flushing pressure is progressively increased based on job requirements
   • Safety practices are applied following OSH
3. Visual inspection of of workpiece and cutting wire
   • Working table is emptied of deionized water according to operating manual
   • Surface of workpiece is cleaned according to job requirement
   • Surface texture of workpiece is visually inspected while on its holder according to job requirements
   • Tension of cutting wire is inspected and corrected/adjusted if necessary according to job requirements
   • Safety practices are applied following OSHS

UNIT OF COMPETENCY : PERFORM POST CNC ELECTRIC DISCHARGE MACHINE (EDM) -WIRE CUT OPERATION
UNIT CODE : MEE 821320

This unit covers the knowledge and skills required to perform post- electric discharge machine wire cut operations.

1. Conduct post CNC EDM wire cut operation
   • EDM flushing is shut off or gate valve is opened in accordance to operation manual
   • Workpiece is removed from work holding and clamping devices according to job requirement
   • Workpiece is cleaned and dried according to job requirement
   • Safety practices are applied following OSHS
2. Final check workpiece
   • Workpiece is checked and measured using measuring tools following standard operating procedures
   • Inspected workpiece is applied with anti-corrosion agents
   • Accomplishment report is filled up according to company procedures
   • Inspected workpiece and accomplishment report are submitted to immediate supervisor following workplace procedures
   • Safety practices are applied following OSHS
3. EDM wire cut shutdown and housekeeping
   • EDM is shutdown according to manufacturer’s operating manual
   • Tools are maintained and stored based on established procedures
   • Defective tools are tagged and reported according to workplace procedures
   • Good housekeeping is performed following 5S
   • Wastes are disposed according to waste management procedures and environmental regulations
   • Safety practices are applied following OSHS

COMMON COMPETENCIES

UNIT OF COMPETENCY : APPLY SAFETY PRACTICES
UNIT CODE : MEE722201

This unit covers the competencies required to apply safety practices in the workplace.

1. Identify hazards
   • Hazards are identified correctly in accordance with OHS principles.
   • Safety signs and symbols are identified and adhered to.
2. Use protective clothing and devices
   • Appropriate protective clothing and devices correctly selected and used in accordance with OHS requirements or industry/ company policy.
3. Perform safe handling of tools, equipment and materials
   • Safety procedures for pre-use check and operation of tools and equipment followed in accordance with industry/ company policies.
   • Tools, equipment and materials handled safely in accordance with OHS requirements and industry/ company policies.
4. Perform first aid
   • First aid treatment of injuries are carried out according to recommended procedures.
5. Use fire extinguisher
   • Fire extinguisher selected and operated correctly according to the type of fire.

UNIT OF COMPETENCY : INTERPRET WORKING DRAWINGS And SKETCHES
UNIT CODE : MEE722202

This unit covers the competencies required to read and interpret drawings and sketches.

1. Interpret technical drawing
   • Components, assemblies or objects recognized as required.
   • Dimensions identified as appropriate.
   • Instructions identified and followed as required.
   • Material requirements identified as required.
   • Symbols recognized as appropriate in the drawing.
   • Tolerance, limits and fits identified in the drawing.
2. Prepare freehand sketch of parts
   • Sketch drawn correctly and appropriately.
   • Sketch depicted objects or part appropriately.
   • Dimensions indicated in sketch are clear and correct.
   • Instructions included in sketch are clear and correct.
   • Base line or datum points indicated as required.
3. Interpret details from freehand sketch
   • Components, assemblies or objects recognized as required.
   • Dimensions identified as appropriate.
   • Instructions identified and followed as required.
   • Material requirements identified as required.
   • Symbols recognized as appropriate in the drawing.

UNIT OF COMPETENCY : SELECT AND CUT WORKSHOP MATERIALS
UNIT CODE : MEE722203

This unit covers the skills and knowledge required to select and cut workshop materials.

1. Determine job requirement
   • Plans/ drawings are interpreted to produce component to specification.
   • Sequence of operation is determined to produce component to specification.
2. Select and measure materials
   • Materials are selected according to the requirement of the operation.
   • Materials are measured to required level of accuracy using measuring tools.
   • Measuring tools are used according to manufacturer’s specification.
3. Cut materials
   • Materials are cut according to plans/drawing instruction.
   • Cutting tools/ equipment are used based on manufacturers specification, appropriate techniques or the safety procedure.

UNIT OF COMPETENCY : PERFORM SHOP COMPUTATIONS (BASIC)
UNIT CODE : MEE722204

This unit covers the competencies required to perform
basic calculations using the four fundamental operation.

1. Perform four fundamental operations
   • Simple calculations are performed using four fundamental operations.
2. Perform basic calculations involving fractions and decimals
   • Simple calculations are performed involving fractions and decimals using the four fundamental operations.
   • Decimal are converted into fraction (and vice versa) accurately.
3. Perform basic calculations involving percentages
   • Simple calculations are performed to obtain percentages from information expressed in either fractional or decimal format.
4. Perform basic calculation involving ratio and proportion
   • Simple calculations are performed involving ratio and proportion using whole numbers, fractions and decimals.
5. Perform calculations on algebraic expressions
   • Simple calculations are performed on algebraic expressions using the four fundamental operations.
   • Simple transposition of formulae is carried out to isolate the variable required, involving the four fundamental operations.

UNIT OF COMPETENCY : MEASURE WORKPIECE (BASIC)
UNIT CODE : MEE722205

This unit covers the competencies required to measure workpieces using measuring instruments such as steel rule, Vernier caliper, micrometer, etc.

1. Select and use measuring tools
   • Measuring tools are selected and used according to the level of accuracy required.
   • Measurements taken are accurate to the finest graduation of the selected measuring instrument.
   • Measuring technique used is correct and appropriate to the device used.
2. Clean and store measuring tools
   • Care and storage of devices undertaken to manufacturer’s specifications or standard operating procedures.

UNIT OF COMPETENCY : PERFORM ROUTINE HOUSEKEEPING
UNIT CODE : MEE722206

This unit covers the competencies required to maintain an organized and clean work area.

1. Organize work area
   • Work area maintained in a safe, uncluttered and organized manner according to workshop policy.
   • All tasks carried out safely, effectively and efficiently with minimum inconvenience according to workshop policy.
   • Workshop policies and procedures for tidying work areas and placing items in designated areas applied.
2. Clean work area
   • Shop policies and procedures applied for cleaning work area.
   • Wastes promptly removed and disposed of according to shop policies and environmental requirements.
   • Spills, wastes and other potential hazards reported to appropriate personnel and removed according to shop policies and environmental requirements.
   • Signage promptly displayed in regard to unsafe areas.
   • Consumable

UNIT OF COMPETENCY : PERFORM SHOP COMPUTATIONS (INTERMEDIATE)
UNIT CODE : MEE722207

This unit covers the competencies required to perform calculation involving triangles and tapers.

1. Perform calculations involving triangles
   • Problems involving right triangles are performed using the trigonometric functions.
   • Problems involving non-right triangles are performed using sine and cosine rules.

UNIT OF COMPETENCY : MEASURE WORKPIECE USING ANGULAR MEASURING INSTRUMENTS
UNIT CODE : MEE722208

This unit covers the competencies required to measure workpieces using angular measuring instruments.

1. Select and use angular measuring tools
   • Angular measuring tools are selected and used according to the level of accuracy required.
   • Measurements taken are accurate to the finest graduation of the selected measuring instrument.
   • Measuring technique used is correct and appropriate to the device used.
2. Maintain angular measuring tools
   • Measuring tools are adjusted and maintained to the required accuracy utilizing manufacturer’s or worksite procedures.
3. Clean and store measuring tools
   • Care and storage of devices undertaken to manufacturer’s specifications or standard operating procedures.

UNIT OF COMPETENCY: MEASURE WORKPIECE USING GAGES AND SURFACE TEXTURE COMPARATOR
UNIT CODE: MEE722210

This unit covers the competencies required to measure workpieces using fixed and adjustable gages.

1. Select and use fixed and adjustable gages
   • Appropriate gages are selected and used to undertake the required comparison or measurement using standard operating procedures.
   • Consistent and accurate measurements obtained conforms to drawing specification
   • Measuring technique used is correct and appropriate to the device used.
2. Perform surface texture measurements
   • Surface texture are measured according worksite procedures.
   • Measurements taken are within the level of accuracy required.
3. Clean and store measuring tools
   • Care and storage of devices undertaken to manufacturer’s specifications or standard operating procedures

UNIT OF COMPETENCY : PERFORM PREVENTIVE AND CORRECTIVE MAINTENANCE
UNIT CODE : MEE722211

This unit covers the knowledge and skills required in performing preventive and corrective maintenance such as inspection and repair of hand tools, cleaning and lubrication of machine parts and changing drive pulley and belts.

1. Perform inspection of machine
   • Machine inspected according to worksite procedures.
   • Status/Report recorded on pro-forma or reported orally according to worksite procedure.
2. Perform cleaning and lubricating of machine
   • Machines lubricated as per manufacturer’s recommendation using appropriate tools and materials
   • Fluids and lubricants replaced and/or topped up according to prescribed schedule.
3. Perform minor machine repair and adjustments
   • Minor machine repairs performed according to manufacturer’s instruction or worksite procedures.
   • Machine moving parts adjusted to manufacturer’s specifications.
4. Maintain hand tools
   • Tool cutting ground to recommended specifications
   • Hand tools lubricated and stored according to prescribed procedure

UNIT OF COMPETENCY: OPERATE A PERSONAL COMPUTER
UNIT CODE: ICT311201

This unit defines the competency required to operate a personal computer by: starting the PC, logging in, using and working with files, folders and programs, saving work, and closing down the PC.

1. Start the computer
   • The peripheral devices are properly connected
   • Power is checked and the computer and peripheral devices are switched on
   • Proper logging in and logging off is successfully done
   • The operating system features and functions are accessed and navigated
   • Hardware configuration and other system features are checked
2. Arrange and customize desktop display/ Windows settings
   • The desktop screen or Windows elements are changed as needed
   • Desktop icons are added, renamed, moved, copied or deleted
   • The online help functions are accessed or used as needed
   • Desktop icons of application programs are selected, opened and closed
   • Properties of icons are displayed
   • Computer or desktop settings are saved and restored
3. Work with files and folders (or directories)
   • A file or folder is created, opened, moved, renamed or copied
   • Files are located, deleted and restored
   • Details and properties of files and folders are displayed or viewed
   • Various files are organized for easy lookup and use
   • Files and information are searched
   • Disks are checked, erased or formatted as necessary
4. Work with user application programs
   • Application programs are added, changed, removed or ran
   • User software or application program are installed, updated and upgraded
   • Information/data are moved between documents or files
5. Print information
   • Printer is added or installed and correct printer settings is ensured
   • Default printer is assigned accordingly
   • Information or document is printed on the installed printer
   • Progress of print jobs are viewed and deleted as required
6. Shut down computer
   • All open application programs are closed
   • Computer and peripheral devices are properly shut down

BASIC COMPETENCIES

The BASIC COMPETENCIES refer to non-technical skills (knowledge, skills and attitudes) that everybody will need in order to perform satisfactorily at work and in society and are considered portable and transferable irrespective of jobs and industrial settings.

LEAD WORKPLACE COMMUNICATION (400311319) – This unit covers the knowledge, skills and attitudes required to lead in the effective dissemination and discussion of ideas, information, and issues in the workplace. This includes preparation of written communication materials.

1. Communicate information about workplace processes
2. Lead workplace discussions
3. Identify and communicate issues arising in the workplace

LEAD SMALL TEAMS (400311320) – This unit covers the knowledge, skills and attitudes to lead small teams including setting, maintaining and monitoring team and individual performance standards.

1. Provide team leadership
2. Assign responsibilities
3. Set performance expectations for team members
4. Supervise team performance

APPLY CRITICAL THINKING AND PROBLE – SOLVING TECHNIQUES IN THE WORKPACE (400311321) – This unit covers the knowledge, skills and attitudes required to solve problems in the workplace including the application of problem solving techniques and to determine and resolve the root cause/s of specific problems in the workplace.

1. Examine specific workplace challenges
2. Analyze the causes of specific workplace challenges
3. Formulate resolutions to specific workplace challenges
4. Implement action plans and communicate results

WORK IN A DIVERSE ENVIRONMENT (400311322) – This unit covers the outcomes required to work effectively in a workplace characterized by diversity in terms of religions, beliefs, races, ethnicities and other differences.

1. Develop an individual’s cultural awareness and sensitivity
2. Work effectively in an environment that acknowledges and values cultural diversity
3. Identify common issues in a multicultural and diverse environment

PROPOSE METHODS OF APPLYING LEARNING AND INNOVATION IN THE ORGANIZATION (400311323) – This unit covers the knowledge, skills and attitudes required to assess general obstacles in the application of learning and innovation in the organization and to propose practical methods of such in addressing organizational challenges.

1. Assess work procedures, processes and systems in terms of innovative practices
2. Generate practical action plans for improving work procedures, processes
3. Evaluate the effectiveness of the proposed action plans

USE INFORMATION SYSTEMATICALLY (400311324) – This unit covers the knowledge, skills and attitudes required to use technical information systems, apply information technology (IT) systems and edit, format & check information.

1. Use technical information
2. Apply information technology (IT)
3. Edit, format and check information

EVALUATE OCCUPATIONAL SAFETY AND HEALTH WORK PRACTICES (400311325) – This unit covers the knowledge, skills and attitudes required to interpret Occupational Safety and Health practices, set OSH work targets, and evaluate effectiveness of Occupational Safety and Health work instructions

1. Identify OSH compliance requirements
2. Prepare OSH requirements for compliance
3. Perform tasks in accordance with relevant OSH policies and procedures

EVALUATE ENVIRONMENTAL WORK PRACTICES (400311326) – This unit covers the knowledge, skills and attitude to interpret environmental Issues, establish targets to evaluate environmental practices and evaluate effectiveness of environmental practices

1. Interpret environmental practices, policies and procedures
2. Establish targets to evaluate environmental practices
3. Evaluate effectiveness of environmental practices

FACILITATE ENTREPRENEURIAL SKILLS FOR MICRO-SMALL-MEDIUM ENTERPRISES (MSMEs) (400311327) – This unit covers the outcomes required to build, operate and grow a micro/small-scale enterprise.

1. Develop and maintain microsmall-medium enterprise (MSMEs) skills in the organization
2. Establish and maintain clientbase/market
3. Apply budgeting and financial management skills

DEFINITION OF TERMS

• CNC EDM wire cut – EDM wire cutting uses a metallic wire to cut a programmed contour in a workpiece. Extrusion dies and blanking punches are very often machined by wire cutting. Cutting is always through the entire workpiece. To start machining it is first necessary to drill a hole in the workpiece or start from the edge.
• Computer Program – A series of instruction, in language a machine control unit can understand, that outlines each steps a machine must take to produce a part
• Computer Numerical Control (CNC) – A machine tool microprocessor that permits the creation or modification of parts. The programmed numerical control activates the machine’s servos and spindle drive, and controls the machine operation
• Direct Numerical Control (DNC) – A number of CNC machine in a manufacturing process controlled by one master computer
• Programing – The process of coding machining conditions in which information such as cutter dimensions, cutter movement processing orders, feed rate, or spindle speed all under fixed regulation or specified format which refers to the workpiece drawing to instruct numerically Controlled
• Computer Aided Design (CAD) – The use of graphics oriented computer software for designing and drafting application
• Computer Aided Manufacturing (CAM) – Computer software that generates programs for the operation of NC (numerical control)
• Surface Finish – The degree of variation of a surface roughness or waviness from a reference or normal plane, usually measured in micro inches or micrometer.
• Tolerance – The amount of interference required for two or more parts that are in contact. The amount of variation, over or under required size, permitted on a piece of machine work
• Zero Reference Point – The point on or off the part, chosen by the programmer as being most suitable for programming and machining purposes
• Sequence of operation – The order of steps to be taken to successfully machine a part or perform an operation
• Manual Programming – This refers to the act of creating an NC program entirely through manual calculation
• Automatic Programming – As the geometries to be machine get complex, it become difficult to create program through manual calculation. Such programs are created by the help of a special purpose computer