ELECTRICAL DISCHARGE MACHINING Special Process Instruction TRAINING EDM ELECTRICAL DISCHARGE MACHINING Special Process Instruction SPI-XXX Rev. A 04-09-2010

ADDITIONAL RECOMMENDED TRAINING: Class Name: Intro into EDM 100 This is a web based course (http://www.toolingu.com). This course is recommended for beginner or intermediate personnel not fully familiar with this nonconventional machining method.

SPI-XXX Electrical Discharge Machining Distribute a copy of latest revision of SPI-XXX Electrical Discharge Machining to all training participants. Review the document in its entirety. Key Elements to be reviewed will be addressed in this training instruction. This page was added (Rev. A) to ensure a copy of the SPI-002 Instruction was incorporated in the training curriculum.

SCOPE: To ensure all EDM (Electrical Discharge Machining) is accomplished in accordance with prescribed procedures. To ensure employees, performing this nonconventional machining method, understand the controls and documentation requirements.

DEFINITION: EDM stands for electrical discharge machining. It is a non-traditional method of machining that uses sparks to remove metal. EDM operations commonly take place on wire EDMs and sinker EDMs. EDM offers unique metal removal options.

RESPONSIBILITY: Electrical Discharge Machining personnel are responsible for:   ensuring the drawing and revision number on the Job Traveler are the same as the drawing and revision number in use. ensuring all EDM machining is performed in accordance with previously approved EDM Record Card process/procedures (as applicable).

EDM RECORD CARD: The EDM Record Card is an electronic form for each machine type that contains all of the required parameters, equipment, fixtures, settings, electrode material, etc. For Conventional Machines a specific form is used. For CNC (Computer Numeric Controlled) Machines the program used for the operation is considered the EDM Record Card. Consult (Company Name) Special Process Instruction SPI-XXX for location/storage of EDM Record Cards.

RECORD CARD EXAMPLE CNC MACHINE: The EDM Record Card for the CNC machines is the CNC Program. Revised page (Rev A) changing example to show an approved procedure.

EDM Record Card Requirements for CNC EDM Machines Each CNC EDM machine Type will have a Program Header Guideline sheet as shown defining all of the MINIMUM ELEMENTS required. All items on this form are required on the Program Header of the CNC program. Added this sheet (Rev A) to show the typical elements that must appear on the CNC Program Header.

Part Loading and Verification: Part Loading instructions must be detailed. Once written into the EDM Record Card, follow it to make sure. Part Loading verification must be a physical checking method, i.e., shim stock used to verify part is firmly against location pins, etc.. Added this page (rev. A). The use of a photograph as an aid to the written instructions is recommended.

EDM REQUIREMENTS AND CUSTOMER APPROVAL: NOT ALL OF XXX’S CUSTOMERS CONSIDER EDM A SPECIAL PROCESS. THEREFORE, OBTAINING CUSTOMER APPROVAL IS NOT ALWAYS REQUIRED. PLEASE CONSULT YOUR TEAM LEADER OR THE PROCESS ENGINEERING DEPARTMENT IF YOU ARE NOT SURE.

STRIVING FOR EXCELENCE – WHAT IS NADCAP? Nadcap: the leading worldwide cooperative program of major companies designed to manage a cost-effective consensus approach to special processes & products and provide continual improvement within the aerospace & automotive industries "The Nadcap vision is to “develop a world-class special processor supply-base for the global aerospace industry using a cost-effective industry managed accreditation process”. Without successful teamwork built on mutually trusting relationships, the Nadcap program simply would not have the fuel to make its vision a reality. Here’s to coming together, sharing together, working together, and succeeding together." - Chetan Date, NMC Past Chairperson