Sensing and compensation of tool wear in milling EDM

Bleys, Philip; Kruth, Jean‐Pierre; Lauwers, Bert

doi:10.1016/j.jmatprotec.2003.11.042

Cited by 109 publications

(41 citation statements)

References 7 publications

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“…For example, pulse evaluation (used to calculate electrode wear), which is subsequently compensated for with linear path correction i.e. down-motion of the electrode [3][4] . However, with the on-line method, it is difficult to establish an accurate mathematical model to calculate wear because of the random nature of the milling EDM process.…”

Section: Current Methods For Measuring Wear Inmentioning

confidence: 99%

Electrode wear prediction in milling electrical discharge machining based on radial basis function neural network

Huang

Bai

Zhang

et al. 2009

J. Shanghai Jiaotong Univ. (Sci.)

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Milling electrical discharge machining (EDM) enables the machining of complex cavities using cylindrical or tubular electrodes. To ensure acceptable machining accuracy the process requires some methods of compensating for electrode wear. Due to the complexity and random nature of the process, existing methods of compensating for such wear usually involve off-line prediction. This paper discusses an innovative model of electrode wear prediction for milling EDM based upon a radial basis function (RBF) network. Data gained from an orthogonal experiment were used to provide training samples for the RBF network. The model established was used to forecast the electrode wear, making it possible to calculate the real-time tool wear in the milling EDM process and, to lay the foundations for dynamic compensation of the electrode wear on-line. This paper demonstrates that by using this model prediction errors can be controlled within 8%.

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Section: Current Methods For Measuring Wear Inmentioning

confidence: 99%

Electrode wear prediction in milling electrical discharge machining based on radial basis function neural network

Huang

Bai

Zhang

et al. 2009

J. Shanghai Jiaotong Univ. (Sci.)

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“…Manufacturing of electrodes of special composition is expensive and not always cost effective. In order to maintain the accuracy of machining, EW compensation has been reported to be an effective technique, where wear was continuously evaluated by sensors and the compensation was made (Bleys et al, 2004). Some researchers have tried to develop mathematical models to optimize the EW and MRR (Puertas et al, 2004;Kunieda et al, 2004).…”

Section: Micromachiningmentioning

confidence: 99%

Role of Heat Transfer on Process Characteristics During Electrical Discharge Machining

Khan¹

2011

Developments in Heat Transfer

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“…Wang et al [14] studied the layer-by-layer processing technology of micro-EDM milling process. Bleys et al [15] presented real-time tool wear sensing and compensation in layer-bylayer EDM milling based on discharge pulse evaluation to estimate electrode wear online with a mathematical model of the sparking frequency. Aligiri et al [16] also presented a compensation method to estimate material removal volume by counting the number of discharge pulses.…”

Section: Introductionmentioning

confidence: 99%

“…To improve machining efficiency, Yan et al [17] proposed an electrode wear compensation method in micro-EDM using an optical measurement of the tool electrode. However, the proposed compensation approaches [15][16][17] heavily rely on sophisticated monitoring systems or optical measure systems, which limit their practical applications.…”

Section: Introductionmentioning

confidence: 99%

A New Measurement Method of Relative Volume Wear Ratio Based on Discharge Debris Composition Analysis in Micro-EDM

Liu

Jia

Zou

et al. 2014

Advances in Mechanical Engineering

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In microelectrical discharge machining (micro-EDM) milling process, due to the unavoidability of electrode wear, selection of electrode with high electrical erosion resistance and accurate electrode compensation is entitled to be conducted to ensure high precision and high quality. The RVWR is used as criterion for electrode wear characteristics and is fundamental to achieve accurate electrode compensation; however, it is hardly measured accurately with conventional methods. In this paper, firstly, the error of RVWR measured by conventional measurement method is analyzed. Thereafter, for accurately measuring RVWR, a new measurement method is proposed based on electrical debris composition analysis. The RVWR of widely used tungsten, molybdenum, and copper electrode in machining different materials is measured, respectively, and the optimum electrode is selected based on the measuring results. Finally, microgrooves on different materials are machined with tungsten electrode, and the experiment results show that the microstructures have good bottom surface profiles, which indicates that the proposed method is effective to precisely measure the RVWR and guarantee accurate electrode compensation in micro-EDM process.

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Sensing and compensation of tool wear in milling EDM

Cited by 109 publications

References 7 publications

Electrode wear prediction in milling electrical discharge machining based on radial basis function neural network

Electrode wear prediction in milling electrical discharge machining based on radial basis function neural network

Role of Heat Transfer on Process Characteristics During Electrical Discharge Machining

A New Measurement Method of Relative Volume Wear Ratio Based on Discharge Debris Composition Analysis in Micro-EDM

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