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Sunday, June 29, 2014

CNC Electric Discharge Machining (Die Sinker)

Introduction

Electric discharge machining (EDM) is process that uses electrical sparks to machine metals into desired shape. EDM is usually used for hard metals or those that would be difficult to machine with conventional techniques. Using Computer Numerical Control (CNC) technology, EDM process is made accurate and programming method can be simplified for effective production. This course focuses on EDM die sinker process where electrode is used to create cavity on the workpiece. Participants will have opportunity to learn the basics of CNC EDM die sinker process including operation method and programming.

Target Group

This course is suitable for persons from machining related industries for example machinist or machine operators who want to learn how to operate a CNC EDM die sinker machine. This course is also suitable for experienced personnel who wish to refresh their knowledge in EDM.

Prerequisites

This course is a basic-level course. Prior knowledge of CNC is not necessary to enroll in this course.

Objectives

Upon completion of the course, the participants should be able to:

            Use proper and safe procedure for operating a CNC EDM machine
      Write simple programs for EDM
            Determine appropriate machining conditions based on work piece or product requirement
      Determine proper tools for machining
           Test run program on an actual CNC EDM

Content

           The Basics
a.       Machining preparation & setup
b.      Method of clamping & confirming parallelism
c.       Operations during machining
d.      Configuration of portable operation panel
e.      Manual operation
           Operating using the main panel
a.       Basic functions
b.      Address keys & numeric symbols
c.       Machining status display areas
       Model plan menus
a.       Machining model plan
b.      Positioning model plan
c.       Measuring model plan 
d.      Auxiliary model plan
       Programming
a.       Program structure and format
b.      Using the Edit screen
c.       Programming input example
        Machining
a.       Electrode reduction
b.      Automatic machining operation
c.       Machining method
d.      Jump pattern and setting
e.      Model monitor screen
f.        Selection and use of model data
g.       Model plan applications
h.      G & M code explanation / examples

Training Method

Training will be delivered through short lecture, demo and practical lesson. The emphasis for this course is on hands on practical sessions.

Schedule

Day 1
08:30 a.m.           Registration
09:00 a.m.           Introduction / preparation & set-up for machining
10:30 a.m.           Break
11:00 a.m.           Operation with portable operation panel
01:00 p.m.          Lunch
02:15 p.m.          Model plan menus and explanations
05:00 p.m.          End of day 1.

Day 2
08:30 a.m.           Program structure & standard format
10:30 a.m.           Break
11:00 a.m.           Automatic machining operation
01:00 p.m.          Lunch
02:15 p.m.          Model plan applications / cutting
05:00 p.m.          End of day 2

Day 3
08:30 a.m.           G and M codes explanation and examples / project
10:30 a.m.           Break
11:00 a.m.           Cutting / Project
01:00 p.m.          Lunch
02:15 p.m.          Question & Answer
05:00 p.m.          Closing ceremony

Fees


Companies sending their employees to this course may apply for reimbursement from Human Resource Development Fund under the SBL scheme.
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Tuesday, June 24, 2014

SYSTEMATIC OPERATION OF INJECTION MOULDING MACHINE





Introduction
Injection moulding is a major manufacturing process in producing parts from both thermoplastic and thermoset plastic materials. Injection moulding is widely used for manufacturing various geometry of parts, from the smallest component to entire body of cars component.


Objectives
Upon completion of the course, the participants should be able to:
a)        Operate injection moulding machine with better understanding about machine and its capabilities.
b)       Operate machine with fill and pack procedure.
c)        Translate machine data into a certain useful documentation.
d)       Use proper and safe procedure when operating injection moulding machine.
e)       Optimise the injection moulding process with is prescribe the part quality.
f)         Determine common moulding problems, their causes and remedies.


Course contents
1.          The terminologies and machine overview
2.          The injection moulding process
Mould construction and component
-   Basic mould design
-   Clamping Tonnage calculation
-   Clamping parameter set-up
3.          Introduction of plastic material
-   Type of polymerisation process
-   Type of plastic material
-   Setting up temperature parameter
4.          Setting up Injection parameter
-   Mould filling study
-   In mould rheology curve
-   Injection speed linearity
-   Cavity imbalance
-   Determine of holding phase
-   Determine of gate freeze of time
-   Determine of melt cushion
5.          Process optimization
-          Injection Pressure limitation
-          Injection speed limitation
-          Clamping force limitation
-          Cycle time limitation
-          Pressure loss study
-          Load sensitivity study
-          Tie bar usage guide


Training Method
Training will be delivered through a combination between theoretical   talk, demonstration and practical lessons.


Target Group
This injection moulding course is designed to improve the moulding process from traditional method to systematic approach of injection moulding operation.  The course is suitable to all personnel, who ever involve in injection moulding manufacturing such as lecturer, manager, engineer, machine operators, quality inspector or process technicians.


Course Instructor
The instructor for this course is Mr. Mohamad Rizuaden Bin Razali, who is an instructor of plastic technology since 2001 at ILP Jitra. Mr. Mohamad Rizuaden Bin Razali also has a 6 years of industrial experience in injection moulding process. He has taught many courses on plastic technology to both local and international participants. Mr. Mohamad Rizuaden Bin Razali is certified as a master moulder 1 by  RJG INC (USA).


Course Schedule
Day 1
08:30 a.m.       Briefing & Registration
09.00 a.m        Injection moulding & machine overview
10:00 a.m        Break
10:30 a.m.       Cont.
01:00 p.m.       Lunch
02:00 p.m.       Practical machine operation & parameter setting
05:30 p.m.       End of day 1







Day 2
08:30 a.m.       Clamping unit & mould design
10:00 a.m        Break
10:30 a.m.       Cont.
01:00 p.m.       Lunch
02:00 p.m.       Practical machine operation & parameter setting
05:30 p.m.       End of day 2

Day 3
08:30 a.m.       Basic hydraulic application
10:00 a.m        Break
10:30 a.m.       Cont.
01:00 p.m.       Lunch
02:00 p.m.       Practical machine operation & parameter setting
05:30 p.m.       End of day 3

Day 4
08:30 a.m.       Basic polymer
10:00 a.m        Break
10:30 a.m.       Cont.
01:00 p.m.       Lunch
02:00 p.m.       Practical machine operation & process optimization
05:30 p.m.       End of day 4

Day 5
08:30 a.m.       Plastic temperature injection phase
10:00 a.m        Break
10:30 a.m.       Cont.
01:00 p.m.       Lunch
02:00 p.m.       Practical machine operation & process optimization
05:30 p.m.       End of day 5

Day 6
08:30 a.m.       Holding phase and cooling phase
10:00 a.m        Break
10:30 a.m.       Cont.
01:00 p.m.       Lunch
02:00 p.m.       Practical machine operation & process optimization
05:30 p.m.       End of day 6



Day 7
08:30 a.m.       Injection moulding economic
10:00 a.m        Break
10:30 a.m.       Cont.
01:00 p.m.       Lunch
02:00 p.m.       Practical machine operation & process optimization
05:30 p.m.       End of day 7


Day 8
08:30 a.m.       Trouble elimination
10:00 a.m        Break
10:30 a.m.       Cont.
01:00 p.m.       Lunch
02:00 p.m.       Practical machine operation & process optimization
05:30 p.m.       Closing ceremony


Contact Person
To obtain more information regarding this course, please contact Corporate and Lifelong Learning Section. (04- 9161926 ext 161 or 162). You can also send enquiries by email to bklh@ilpjitra.gov.my


Fees
Companies sending their employees to this course may apply for reimbursement from HRDF under the SBL scheme.
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ILP Jitra - Leader In Skills Excellence


i)Vision : To be a leading organization in the development of competitive workforce

ii)Mission: To produce competent workforce

iii)Objectives:
i-To aide in the direction of optimum utilization of Manpower through Industrial Training Programs.

ii-To improve the standard of skills among workers in the industrial sector.

iv)Core Values:

Access and Equity- Our services are available to everyone who needs them

Quality- A qualification from us should be acknowledged as a sign that the person has received quality training

Continuous improvement- We are always looking for ways to improve services to our clients

Respect for industry -We adapt our services to meet the needs of industry

Integrity -We are committed to the highest standards of ethical behavior

Community -We build partnerships with people and organizations who share our ideals so that together we can achieve more for our clients

Service- We exist to serve our country and industry

v)Corporate Strategy:

Our experienced course managers will serve as strategic partners in order to understand your specific business needs, challenges and requirements. Our consultative and collaborative approach allows our team to develop a sound strategy with clear objectives and outcomes. The insight we gain through our strategic approach will ensure your business receives competency-based, innovative and results-driven training, by the best trainers in the business.

vi)Quality Policy:

A qualification from us should be acknowledged as a sign that the person has received quality training

Please explain the method of formulating the corporate strategy

Experienced course managers will serve as strategic partners in order to understand your specific business needs, challenges and requirements .We will use CUDBASS techniques to find out the weakness and come out with the best solution to narrow down the gap among employees and help clients to boost their performance and profitability.


TRAINING PROGRAM DEVELOPMENT
All training programs including its curriculum structure developed follow National Occupational Skills Standards (NOSS). NOSS is a document that outlines the dexterity required of an employee working in Malaysia at a certain level of employment to achieve specific skills. This Standard was prepared by industry experts and skilled workers in related fields. Its help Skills Training Institute /Trainer/Instructor:
i. To develop an appropriate training curriculum which meets industry needs
ii. To design a full-time training program or customized program that meets industry needs
iii. To have a clearer understanding of the skills required by the industry
iv. Basic assessment of re- training needs of instructors/trainers to meet current industry needs
v. Proper career advice may be given effectively to trainees.

Describe the approaches implemented by your company in ensuring quality training programs.
i) Identification of training needs of employers/industries(Please attach any study, market intelligence or survey conducted).

All the training contents will be developed base on NOSS requirement to ensure the skill training programs meets the industry needs and eliminating miss match/gap between training provider and industry /employers needs. It’s also giving us a clear and systematic approach on how to provide skill training to help company and employee to enhance their career.


ii) Internal factors, including upgrading of trainers’ skills (Please provide evidence).

We train our Trainer/Instructor on related skills areas to improve their knowledge, skills and attitude to become the best trainer in skill training every year including sponsored their participation in Malaysia Skill Competition.


Briefly explain the effort put for continuous improvement of the training programs.

We are establishing Corporate and Lifelong Learning Division to lead on continuous improvement of the training programs and worked with the industry on how to produce competent workers.
CUDBASS method will help us to develop special and workable training programmes to benefit our clients.

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