key responsibilities
1. programming & cad/cam
program generation: using cam software (like esprit, mastercam, or peps) to convert 2d or 3d cad files into g-code for the wire machine.
taper & complex cutting: programming specialized cuts, including 4-axis taper cutting where the top and bottom of the wire move independently.
simulation: running digital simulations to check for collisions and ensure the wire path is efficient.
2. setup & machine operation
workholding: clamping and aligning raw materials on the machine bed, often ensuring alignment within .
threader management: monitoring and maintaining the automatic wire threader (awt) to ensure the machine runs unattended (lights-out manufacturing).
parameter adjustment: setting the correct voltage, pulse frequency, and flushing pressure based on material thickness and type.
3. quality & maintenance
precision inspection: verifying parts using profile projectors, micrometers, and cmms (coordinate measuring machines).
consumable tracking: managing the supply of deionized water (resin), wire spools, and filters.
troubleshooting: resolving issues like wire breakage or surface finish irregularities.