EDM Drilling optimisation using stochastic techniques

Maradia, Umang; Benavoli, Alessio; Boccadoro, Marco; Bonesana, Claudio; Kliuev, Mikhail; Zaffalon, Marco; Gambardella, Luca Maria; Wegener, Konrad

doi:10.1016/j.procir.2017.12.225

Cited by 11 publications

(6 citation statements)

References 13 publications

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“…A possible algorithm to optimize the processing parameters could be based on a stochastic optimization technique [36]. However, in comparison with a previous application of this technique [6], the processing parameters could be varied during the drilling process of a single hole when following an approach based on in-line monitoring of fr . This would reduce the amount of time spent in each optimization iteration.…”

Section: Resultsmentioning

confidence: 99%

“…It follows that significant post-processing metrology efforts are often required for quality control and tolerance verification of micro-EDMed holes. Recent advancements in machine learning techniques offer new solutions for shortening and automating process optimization and allow for the creation of technology databases to reduce post-process metrology [5,6]. However, effective and reliable approaches for correlating the processing parameters and the relevant outputs in terms of efficiency of the drilling process and hole quality are needed for these purposes.…”

Section: Introductionmentioning

confidence: 99%

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Process Fingerprint in Micro-EDM Drilling

2019

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The micro electrical discharge machining (micro-EDM) process is extensively used in aerospace, automotive, and biomedical industries for drilling small holes in difficult-to-machine materials. However, due to the complexity of the electrical discharge phenomena, optimization of the processing parameters and quality control are time-consuming operations. In order to shorten these operations, this study investigates the applicability of a process fingerprint approach in micro-EDM drilling. This approach is based on the monitoring of a few selected physical quantities, which can be controlled in-line to maximize the drilling speed and meet the manufacturing tolerance. A Design of Experiments (DoE) is used to investigate the sensitivity of four selected physical quantities to variations in the processing parameters. Pearson’s correlation is used to evaluate the correlation of these quantities to some main performance and hole quality characteristics. Based on the experimental results, the potential of the process fingerprint approach in micro-EDM drilling is discussed. The results of this research provide a foundation for future in-line process optimization and quality control techniques based on machine learning.

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Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Process Fingerprint in Micro-EDM Drilling

2019

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“…Many different researchers have investigated minimizing electrode wear and, thus, the hole taper angle. During the EDM drilling of difficult-to-cut materials, especially in micromachining, preventing electrode wear means enhancing productivity [37].…”

Section: Resultsmentioning

confidence: 99%

Self-Flushing in EDM Drilling of Ti6Al4V Using Rotating Shaped Electrodes

Goiogana

Elkaseer

2019

Materials

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This article reports an experimental investigation of the efficacy of self-flushing in the Electrical Discharge Machining (EDM) process in terms of tool wear rate (TWR), hole taper angle and material removal rate (MRR). In addition to a plain cylindrical shape, electrodes of different cross sections (slotted cylindrical, sharp-cornered triangular, round-cornered triangular, sharp-cornered square, round-cornered square, sharp-cornered hexagonal and round-cornered hexagonal) were designed as a means of inducing debris egress and then fabricated in graphite. EDM drilling trials using the rotating shaped electrodes were carried out on a Ti6Al4V workpiece. The results revealed that, although a low TWR and minimum hole taper angle were achieved using a plain cylindrical electrode, the usage of rotating shaped electrodes provided self-flushing of the dielectric fluid during the EDM process, which led to an improvement in MRR compared to that achieved with a plain cylindrical electrode. Besides, in general, the electrodes with rounded corners are associated with a lower TWR, a lower hole taper angle and a higher MRR when compared to the electrodes with sharp corners. Considering these results, it was concluded that different process attributes, i.e., TWR, hole taper angle and MRR, are all greatly affected by the electrode shape, and thus, the proper selection of the electrode shape is a precondition to attain a specific response from the EDM process.

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“…The performance of the optimization algorithm is further evaluated in terms of effect of initial parameters and number of iterations required to converge to the optimal parameter values, to achieve highest material removal rate (MRR). It is found that the optimization algorithm is able to turn up at the optimal values after ∼40 iterations, where the achieved MRR is at least 10% higher than the MRR obtained by using the high-speed strategy from the standard machine technology [126].…”

Section: Modeling and Optimization Of Surface Qualitymentioning

confidence: 86%

A review on optimization of machining performances and recent developments in electro discharge machining

Nahak

Gupta

2019

Manufacturing Rev.

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Electro discharge machining (EDM) is a popular unconventional machining process widely employed in die-making industries. Careful selection of process parameters such as pulse current, voltage, on and off time, etc. is essential for machining of hard and conductive materials using EDM. Previous researchers working in the area of EDM have extensively analyzed the machining performance through experimental study, modeling, and simulation and also by theoretical analysis. This article discusses the significant summary of the work performed by earlier researchers through a detailed literature survey. Relevant literature on EDM and impact of process parameters on performance measures such as surface quality, tool wear rate and material removal rate are reviewed. The challenge and limitation of EDM process are also highlighted in this article. It is observed that optimization of process parameters is essentially required for effective and economical machining. So, this article addresses the various issues related to EDM and also provides brief insight into some of the current generation applications of EDM process explored in various industries.

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EDM Drilling optimisation using stochastic techniques

Cited by 11 publications

References 13 publications

Process Fingerprint in Micro-EDM Drilling

Process Fingerprint in Micro-EDM Drilling

Self-Flushing in EDM Drilling of Ti6Al4V Using Rotating Shaped Electrodes

A review on optimization of machining performances and recent developments in electro discharge machining

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