The analysis of EDM electrodes wear in corners and edges

Mouralová, Kateřina; Bednár, J; Beneš, Libor; Hrabec, Pavel; Kalivoda, Milan; Fries, Jiří

doi:10.1007/s43452-020-00137-8

Cited by 12 publications

(7 citation statements)

References 23 publications

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“…The main processing parameters include processing polarity, interelectrode voltage, peak current, pulse frequency, pulse width, and tool electrode and workpiece electrode gap. 28,29 Among the above parameters selected in this test, the polarity parameters are two levels (positive and negative polarities), and the other five parameters are three levels. The design of a mixed 2--3 level L 18 orthogonal array containing 6 columns and 18 rows, namely L 18 (2 1 × 3 5 ), can significantly reduce the number of tests.…”

Section: Experimental Design and Resultsmentioning

confidence: 99%

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Performance prediction and parameter optimization of alumina-titanium carbide ceramic micro-EDM hole machining process based on XGBoost

Chen

Cheng

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part L:

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Aiming at the difficulties in setting process parameters and the low accuracy of process performance prediction in electrical discharge machining (EDM) hole machining of alumina ceramics, a novel EDM process performance prediction method based on eXtreme Gradient Boosting (XGBoost) is proposed in this study. The independent variables selected include processing polarity (P), interelectrode voltage (V), peak current (I), pulse frequency (F), pulse width (T), and tool electrode and workpiece electrode gap (W), while the dependent variables are tool electrode length loss (ELW), tool electrode volume loss (EVW), and material removal rate (MRR). An L18 (21 × 35) orthogonal test is designed to obtain training samples for model development. The accuracy of the prediction results for ELW, EVW, and MRR by the XGBoost model is found to be 1.7%, 2.5%, and 9.4%, respectively. These results show a significant improvement compared to the linear regression model, with an improvement of 41.7%, 62.5%, and 19.4%, respectively. Furthermore, when compared to the support vector regression (SVR) model, the XGBoost model also shows improvement of 23.6%, 5.9%, and 12.0% for ELW, EVW, and MRR prediction accuracy, respectively. These findings suggest that the proposed XGBoost-based method is effective and accurate in predicting the performance of alumina ceramic EDM processes. In addition, the third generation nondominated sorting genetic algorithm (NSGA-III) is utilized to optimize the process parameters with both single objective and multi-objective approaches. The optimal parameters for ELW, EVW, and MRR, including the selection of machining polarity, interelectrode voltage, peak current, pulse frequency, pulse width, and tool electrode and workpiece electrode gap are obtained through the Pareto frontier of the three comprehensive optima. The average relative errors between the experimental results and the optimized results are found to be 6.46%, 10.45%, and 9.58% for ELW, EVW, and MRR, respectively, indicating the accuracy and effectiveness of the optimized results.

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Section: Experimental Design and Resultsmentioning

confidence: 99%

“…The main processing parameters include processing polarity, interelectrode voltage, peak current, pulse frequency, pulse width, and tool electrode and workpiece electrode gap. 28,29…”

Section: Orthogonal Testmentioning

confidence: 99%

Performance prediction and parameter optimization of alumina-titanium carbide ceramic micro-EDM hole machining process based on XGBoost

Chen

Cheng

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part L:

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“…The novelty of this study lies mainly in the use of the same material for the workpiece and for the tool, all in micro dimensions. This study builds on previous studies on EDM, such as the corner wear electrode study [5] or the study on defects occurrence while machining steels 1.2363 and 1.2343 ESR [6]. The results of this study can be used not only in the production of a key part for optical devices designed for testing car lights, but also for the production of other parts from thin films.…”

Section: Introductionmentioning

confidence: 86%

Micro-EDM Machining With Copper Foil

Mouralová

Bednár

Beneš

et al. 2021

Preprint

Self Cite

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Electrical discharge die-sinking machining (EDM) is one of the indispensable unconventional technologies enabling the machining of all materials that are at least minimally electrically conductive. Due to the clear trend of miniaturization of products, it is necessary to ensure their quality and accurate production, also with the help of micro-EDM. It is the optical instruments used for testing car lights that contain these miniaturized parts necessary for the correct functioning of the device. For this reason, this study was performed, which focused on the production of a precise slot measuring 5000x170 µm in a copper foil with a thickness of 125 µm. The same copper foil was used as a tool, which represents an advance in the production of micro-parts. A design of experiment Box and Behnken Response Surface Design was performed for a total of 15 rounds, monitoring the effect of machine setting parameters (Pulse current, Pulse on time and Voltage) on responses in the form of Erosion rate, corner radius, slot length and width. Using multi-criteria optimization, the optimal setting of the machine parameters for the production of a given slit was determined, which is Pulse current = 2.1 A, Pulse on time = 40 µs and Voltage = 238.8 V.

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“…They only buy copper foil, which they use both for the product itself and as a machining tool. This study builds on previous studies on EDM, such as the corner wear electrode study 5 or the study on defects occurrence while machining steels 1.2363 and 1.2343 ESR 6 . The results of this study can be used not only in the production of a key part for optical devices designed for testing car lights, but also for the production of other parts from thin films.…”

Section: Introductionmentioning

confidence: 99%

Production of precision slots in copper foil using micro EDM

Mouralová

Bednár

Beneš

et al. 2022

Sci Rep

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Electrical discharge machining (EDM) is an unconventional machining technology. It allows machining of at least at least electrically conductive materials. The trend of miniaturization of industrial products is obvious. However, the required quality and accuracy must be maintained, which can be achieved with micro-EDM. One of the industrial products is also optical devices used for testing cars. These contain miniaturized parts, which are, however, necessary for their proper functioning. For this reason, this study was performed, which focused on the production of a precise slot measuring 5000 × 170 µm in a copper foil with a thickness of 125 µm. The same copper foil was used as a tool, which represents an advance in the production of micro-parts.The use of the same semi-product for the production of the slit as well as the tool itself has not yet been presented in any similar study. A design of experiment Box and Behnken Response Surface Design was performed for a total of 15 rounds, monitoring the effect of machine setting parameters (Pulse current, Pulse on time and Voltage) on responses in the form of Erosion rate, corner radius, slot length and width. Using multi-criteria optimization, the optimal setting of the machine parameters for the production of a given slit was determined, which is Pulse current = 2.1 A, Pulse on time = 40 µs and Voltage = 238.8 V. Micro-EDM technology has been found to be suitable for the production of miniaturized slits.

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The analysis of EDM electrodes wear in corners and edges

Cited by 12 publications

References 23 publications

Performance prediction and parameter optimization of alumina-titanium carbide ceramic micro-EDM hole machining process based on XGBoost

Performance prediction and parameter optimization of alumina-titanium carbide ceramic micro-EDM hole machining process based on XGBoost

Micro-EDM Machining With Copper Foil

Production of precision slots in copper foil using micro EDM

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