A self-learning fuzzy controller for wire rupture prevention in WEDM

Abstract

Wire breaking is a serious problem in the application of wire electrical discharge machining (WEDM

Wire EDM failure prediction and process control based on sensor fusion and pulse train analysis

“…Wire EDM failure prediction and process control based on sensor fusion and pulse train analysis. International Journal of Advanced Manufacturing Technology , 118 (5)(6), 1453-1467. https://doi.org/10.1007/s00170-021-07974-8 consumption, and machined part rejection due to surface damage. In order to achieve complete automation and to improve the competitiveness of the process, failure situations shall be predicted and avoided.…”

“…Many fuzzy logic wire break prediction models based on spark energy and frequency were developed in this regard. Yan and Liao [5] developed a fuzzy logic wire break prediction system by monitoring spark frequency. Pulse off time is auto regulated to keep spark frequency within limits.…”

“…A severity based variable process control, as proposed in this study, is not investigated before. Fuzzy logic is the most commonly used soft computing algorithm for wire EDM condition monitoring [5][6][7]. However, fuzzy logic is based on operators experience and a rule set connecting parameters and responses.…”

ANFIS modelling of mean gap voltage variation to predict wire breakages during wire EDM of Inconel 718

“…The offline model aids in the initial input parameter settings and online model detects the defects in real time. Yan and Liao [8] developed a fuzzy logic-based model to prevent wire ruptures during wire-EDM. The model detects the sparking frequency in real-time and adjusts the pulse off time to reduce the frequency to safe limits.…”

Real-Time Monitoring and Diagnosis Platform for a Machining Process

“…However, WEDM has a strong stochastic nature whose features depend definitely on the machining parameters. Therefore, accurate modelling is difficult if not impossible (Yan, et al, 1996).…”