Design of Real-Time Extremum-Seeking Controller-Based Modelling for Optimizing MRR in Low Power EDM

Abstract

Electric discharge machining (EDM) is one of the non-conventional machining processes that supports machining for high-strength and wear-resistant materials. It is a challenging task to select the process parameters in real-time to maximize the material removal rate since real-time process trials are expensive and the EDM process is stochastic. For the ease of finding process parameters, a modelling of the EDM process is proposed. Due to the non-linear relationship between the material removal rate (MRR) and discharge time, a model-free adaptive extremum-seeking controller (ESC) is proposed in the feedback path of the EDM process for finding an optimal value of the discharge time at which the maximum material removal rate can be achieved. The results of the model show a performance that is closer to the actual process by choosing steel workpieces and copper electrodes. The proposed model offers a lower error rate when compared with actual experimental process data. When compared to manual searching for an optimal point, extreme seeking online searching performed better as per the experimental results. It was observed that the experimental validation also proved that the ESC can produce a large MRR by tracking the extremum control. The present study has been limited to only the MRR, but it is also possible to implement such algorithms for more than one response parameter optimization in future studies. In such cases the performance measures of the process could be further enhanced, which could be used for a real-time complex die- and mold-making process using EDM.

Improving Micro-EDM Machining Efficiency for Titanium Alloy Fabrication with Advanced Coated Electrodes

“…Additionally, the presence of Al, Cr, and N elements suggests potential advantages such as improved mechanical properties and the potential to replace costly surface spray methods like PVD, PVC, etc. The protective role of the coating on the base electrode during machining contributes to enhanced working conditions of the electrode in micro-EDM [ 23 , 24 ].…”

Recent Trends and Developments in the Electrical Discharge Machining Industry: A Review

“…Various process control systems have been proposed to enhance EDM quality [23,94,234,235], including fuzzy logic-based control [23], inverse modeling [94], and adaptive control systems that monitor the spark ratio as an indicator of gap voltage [234]. Another approach involves control focused on maximizing MRR by dynamically optimizing the unloading time [235]. The advancement of smart manufacturing in EDM will see greater progress with the expansion of mathematical and computer modeling capabilities.…”