Spark Erosion Training Course: Advanced

Introducing the Wire Erosion Training Course

The Advanced Wire Erosion Training Course is designed for experienced operators who want to deepen their technical capability and push performance, accuracy and efficiency further.

This course goes beyond fundamentals, focusing on complex programming, multi-axis machining, advanced taper work and machine optimisation. Training is practical, hands-on and tailored to real production challenges faced on the shop floor.

Advanced courses are typically delivered over 2–4 days, depending on machine type, experience level and objectives.

Machine Operating Procedure

Reinforce best practice while working at an advanced level.

This module revisits machine operating procedures with a focus on working confidently through more complex setups and machining scenarios. Delegates will understand how advanced operations impact machine behaviour, accuracy and reliability.

Outcome:
Operate the machine with confidence during complex and high-precision machining tasks.

CAD & Manual Programming

Develop greater control over programming methods.

Delegates will work with both CAD-generated and manually created programs, understanding when each approach is best suited. Emphasis is placed on editing, refining and optimising programs directly at the control.

Outcome:
Confidently create, modify and manage complex programs using CAD and manual programming methods.

Practical 2D Programmes

Refine accuracy and efficiency in 2D machining.

This section focuses on producing precise 2D programs, reinforcing accuracy, geometry control and efficient cutting strategies used in real production environments.

Outcome:
Produce reliable, accurate 2D programs that perform consistently in production.

Practical Standard Taper

Machine accurate tapers with confidence.

Delegates will learn how to program and machine standard tapers correctly, understanding the relationship between taper angles, machine settings and finished part accuracy.

Outcome:
Machine standard tapers accurately and repeatably to specification.

Practical 4-Axis Programming

Unlock the full capability of the machine.

This module introduces practical 4-axis wire erosion programming, focusing on real-world applications rather than theoretical complexity. Delegates will understand machine movement, synchronisation and control across multiple axes.

Outcome:
Confidently programme and run 4-axis jobs for more complex component geometry.

Land & Taper Programming

Combine straight and tapered features accurately.

Delegates will be shown how to program parts requiring both land and taper features, managing transitions smoothly and maintaining dimensional control throughout the cut.

Outcome:
Produce parts with combined land and taper features to a high precision standard.

Taper Settings & Setting Procedure

Apply taper settings correctly and consistently.

This section covers selecting, setting and validating taper parameters. Delegates will understand how incorrect settings affect accuracy and how to adjust them to achieve optimal results.

Outcome:
Set and control taper parameters accurately, improving quality and reducing rework.

Technology Settings – Different Materials

Optimise machining across a range of materials.

Delegates will explore how different materials respond to wire erosion machining and how to adjust technology settings accordingly. The focus is on surface finish, accuracy, stability and efficiency.

Outcome:
Apply the correct technology settings for different materials to achieve consistent, high-quality results.

Graphic Screen – Drawings

Use the graphic screen to verify and validate programs.

Delegates will learn how to interpret drawings on the machine’s graphic screen, using visual feedback to validate geometry, check movement and confirm program intent before cutting.

Outcome:
Visually verify programs and drawings to reduce errors before machining begins.
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Auto Vertical Wire Settings

Improve accuracy through automation.

This module covers the use of auto vertical wire settings, explaining how and when to use them and how they contribute to accuracy, efficiency and repeatability.

Outcome:
Use automated wire settings correctly to improve cut accuracy and consistency.

Edge / Centre / Slot Finding & Dry Run

Refine setup accuracy on complex jobs.

Building on basic techniques, this section focuses on applying edge, centre and slot finding to complex setups, alongside effective dry running of advanced programs.

Outcome:
Set parts accurately and validate advanced programs with confidence before cutting.

Maintenance on the Machine

Understand maintenance that affects machining accuracy.

Delegates will cover key maintenance practices that directly impact machine performance and precision, including checks and adjustments operators should be comfortable carrying out.

Outcome:
Identify and carry out essential maintenance to maintain machine accuracy and reliability.

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Machine Test Cutting – Precision Parts

Put advanced skills into practice.

Delegates will machine test components to demanding tolerances, applying advanced programming, setup and technology selection in a controlled environment.

Outcome:
Produce high-precision parts confidently and consistently using advanced wire erosion techniques.

On completion of the Advanced Wire Erosion Training Course, delegates will have a deep, practical understanding of advanced wire EDM programming, setup and machining.

They will be able to:

• Program complex components using CAD, manual and 4-axis methods
• Apply taper, land and advanced machining strategies accurately
• Optimise technology settings for different materials
• Maintain machine performance and precision
• Machine high-accuracy parts with confidence in demanding environments

This course is ideal for experienced operators looking to maximise machine capability, improve part quality and operate at a higher technical level.