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FOCUSED TRAINING MODULES

HOW TO USE OUR FOCUSED TRAINING MODULES

STEP 1 Review the Lesson Content


Preview the video training lesson for the module to determine which employees at your
facility could benefit from this training. Focus on the following criteria:

· Who would benefit directly from learning this topic?


· Who should know about the concepts covered in this module?

STEP 2 Complete the Training Plan


List all the employees identified in STEP 1 in your TRAINING PLAN for the module. We
recommend that you identify your employees by job description (such as all the technicians or
operators) and use this to track their progress throughout the training initiative.

STEP 3 Have Your Employees Watch the Video Training Lesson


Have each employee on your training plan sit down and watch the video training lesson. We
suggest that you train from the top down: This will help you get everyone on the same page.

STEP 4 Carry out the On-The-Job Training


Identify a few knowledgeable employees who can take the others out to the plant floor and
cover the ON-THE-JOB TRAINING SHEET. Be sure to complete this step within a week of
completing STEP 3.

STEP 5 Quiz Your Employees


Have each employee on your training plan take the TRAINING QUIZ. To pass the test, your
employees must answer at least 3 out of the 4 questions correctly. If they fail the quiz, have
them repeat STEP 3 and STEP 4 before giving them another opportunity to pass the quiz.

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FOCUSED TRAINING MODULE #19
Electrical Discharge Machining (EDM)

TRAINING PLAN

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ww w.t r a i n i n t e r a c t i v e . c o m © A. Routsis Associates, Inc.


FOCUSED TRAINING MODULE #19
Electrical Discharge Machining (EDM)

ON-THE-JOB TRAINING SHEET

Training Facilitator:

Training Participant:

Training Date:

Training Location: In the tooling room in front of the EDM machine with an
electrode in hand. You should also have a piece of paper,
calculator, and pencil.

Explain how the EDM machine functions:


• An electrical charge is applied to the electrode and the opposite charge is applied to the
workpiece
• As the electrode approaches the workpiece, a spark travels between the two
• The spark burns away metal from the workpiece eventually leaving an impression
• The distance between the electrode and the mold surface is the overburn

Show the employee the workpiece in the EDM machine and explain the settings being used and the
expected overburn.

Show the employee some different workpieces and identify the rough finishes left behind from the
EDM machine.

Also show the employee some of the electrodes used at your facility. Explain how they are machined
as well as the materials they are constructed from.

Using the paper draw ask the employee to:


• Draw a rectangle on the paper 2 inches by 1 inch (50mm x 25mm)
• Calculate and enter the electrode dimensional requirements using your company’s typical
overburn settings

ww w.t r a i n i n t e r a c t i v e . c o m © A. Routsis Associates, Inc.


FOCUSED TRAINING MODULE #19
Electrical Discharge Machining (EDM)

TRAINING QUIZ

Facilitator Name:

Participant Name:

Date:

Question #1:
The typical surface left behind from a die sinker EDM machine is generally… (circle one)
A. Smooth
B. Radial
C. Rough

Question #2:
Electrodes are made of non-conductive materials. (circle one)
True or False

Question #3:
If a negative charge is applied to an electrode, then the workpiece would need… (circle one)
A. a negative charge
B. a positive charge
C. to be grounded

Question #4:
Draw an electrode that could be used to machine a 1 inch square using your company’s typical
overburn settings. (write your answer in the space below)

ww w.t r a i n i n t e r a c t i v e . c o m © A. Routsis Associates, Inc.


FOCUSED TRAINING MODULE #19
Electrical Discharge Machining (EDM)

TRAINING QUIZ ANSWERS

Passing Score: 3 of the 4 questions must be answered correctly

Question #1:
The typical surface left behind from a die sinker EDM machine is generally… (circle one)
A. Smooth
B. Radial
C. Rough
Show the employee some different work pieces and identify the rough finishes left behind from the
EDM machine.

Question #2:
Electrodes are made of non-conductive materials. (circle one)
True or False
Electrodes are made from conductive materials, such as graphite or copper.

Question #3:
If a negative charge is applied to an electrode, then the workpiece would need… (circle one)
A. a negative charge
B. a positive charge
C. to be grounded
The electrode is placed into the machine, a positive or negative electrical charge is applied to the
electrode and the opposite charge is applied to the workpiece.

Question #4:
Draw an electrode that could be used to machine a 1 inch square using your company’s typical
overburn settings. (write your answer in the space below)
This is a plant-specific question requiring your input.

ww w.t r a i n i n t e r a c t i v e . c o m © A. Routsis Associates, Inc.