Improvement of EDM Performance With Advanced Monitoring and Control Systems

Abstract

The electrical discharge machining (EDM) process performance depends on maintaining an appropriate machining gap with a servo system and discharge pulse parameters with a pulse power generator. The integration of the state-of-the-art monitoring and control technologies can substantially improve the performance of the EDM process. This paper reviews the research and development of advanced monitoring and control systems for die-sinking EDM and wire EDM during the last two decades. Important research activities include different EDM gap monitoring systems, servo and pulse adaptive control systems, and knowledge base control systems.

Design and tuning of a fuzzy logic controller for micro-hole electrical discharge machining

“…Fuzzy logic control for conventional machining processes has been studied [15,16] and is more popular in EDM research because it has faster response and higher stability [17] and can more accurately model realworld events by allowing the existence of uncertainty to simulate human reasoning [18]. The fuzzy logic controller [19][20][21][22][23][24] has demonstrated the capability to adaptively control the EDM process by handling highly nonlinear processes with only qualitative knowledge [18,25] and reduce the drilling time by minimizing the arc and short circuit pulses [6]. In this study, fuzzy logic control of the micro-hole EDM process is investigated.…”

“…Tel. : +1 734 647 1766. proportional-integral-derivative (PID) controller less competitive in preventing the undesired arc and short circuit pulses for efficient EDM processes [5,6]. Adaptive control of the EDM process has been studied since the late 1970s [7][8][9][10][11].…”

A New Pulse Discriminating System for Micro-EDM

“…However, this method provides inadequate information of gap states, since average gap voltage does not directly show the occurrence of harmful discharges. The conventional control systems for servo and machine parameters are unable to provide any action for avoiding harmful arcing [21]. This is a great threat as arcing can damage the work piece and tool.…”

Dynamic Observer Modeling and Minimum-Variance Self-Tuning Control of EDM Interelectrode Gap

“…where a1, a2, b0, and b1 are model parameters, ( ) u k is the moving position of the electrode, and ( ) y k is the interelectrode gap d. Equation (18) can be written as (19) where…”