Title: Benefits of using real-time pulse discriminating system in micro-EDM monitoring and control system

Authors: E. Aligiri, S.H. Yeo, P.C. Tan, H. Zarepour

Addresses: School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, 639798, Singapore. ' School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, 639798, Singapore. ' School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, 639798, Singapore. ' School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, 639798, Singapore

Abstract: This paper deals with the implementation of real-time pulse discriminating system for monitoring and improving the performance of micro electrical discharge machining (EDM) process. Currently, the average gap voltage information is applied to control micro-EDM process, ensuring that the process takes place in a proper gap state. In this work, a real-time pulse discriminating system is employed as the basic platform of micro-EDM control system for a more detailed interpretation of the state of micro-EDM process. Experimental verifications show that the pulse distributions are good indicators for predicting material removal rate (MRR) and tool wear ratio (TWR) of the ongoing process. Furthermore, the real-time pulse discriminating-based control system is able to shorten the machining time to half, that of a typical control system without pulse discriminating capability and also produce more accurate machined features.

Keywords: micro electrical discharge machining; micro-EDM; real-time pulse discriminating; online monitoring; adaptive control; electro-discharge machining; material removal rate; MRR; tool wear ratio.

DOI: 10.1504/IJMMS.2010.036070

International Journal of Mechatronics and Manufacturing Systems, 2010 Vol.3 No.5/6, pp.466 - 481

Published online: 17 Oct 2010 *

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