Spark location adaptive process control in meso-micro EDM

Abstract

Time-synchronised high-speed imaging and electrical signal measurements are performed in near-real erosion conditions to analyse the feasibility of determining spark location based on its electrical signals in die-sinking electrical discharge machining (EDM). Using this novel research platform, a correlation between the discharge voltage and the geometric location of a discharge on an electrode has been established. Through the derived understanding, a microsecond level spark location adaptive process control has been conceptualised and demonstrated. The parameter control of each spark according to its probabilistic location on the electrode results in low wear of micro- to macroscale electrode features, higher material removal rate and higher form precision despite of electrode complexity. Reduction in the required number of electrodes achieved through the novel spark location adaptive process control increases the economic and energy efficiency of die-sinking EDM.