Abstract
Electrical discharge machining (EDM) is one of the most accurate methods for machining conductive materials and has a number of important applications. In the EDM process the occurrence of electric charges between cathode and anode is accompanied by vibroacoustic signals, which can be used to develop highly efficient control and diagnostics systems. Experimental studies and modelling of the dynamic system of the EDM process carried out in this study show that parameters of acoustic signals can be used to estimate the current productivity and risks of the tool-electrode breakage and to optimize the tool feed rate. The obtained results of allows using acoustic signals in the control system of the tool electrode feed rate to prevent its breakage, and also setting the interelectrode gap to maximum productivity.
Highlights
Electrical discharge machining (EDM) is one of the most high-precision types of machining
EDM process is married with some issues that lead to unsatisfactory quality of the surface being processed, tool-electrode (TE) breakage and damage of the equipment [11,12]
The working area is quite small, with the typical size of less than 0.4-0.5 mm, and located at a distance of at least 1-2 mm from the surface of the dielectric medium in the case of full workpiece immersion [18,19,20] that makes the application of the standard monitoring systems, which are difficult to install in such a way as to have access to the working area, and which cannot deliver critically important information about processes occurring between two electrodes [21,22,23,24], pretty much useless
Summary
Electrical discharge machining (EDM) is one of the most high-precision types of machining. In the existing EDM equipment, monitoring is usually carried out via the indirect control of electrical parameters, characterizing discharge pulses in the interelectrode gap (IEG) [25,26,27,28] such as pattern of the pulses, voltage amplitude, IEG resistivity in the pause between pulses, discharge current, and others [29]. In the case, when the temperature of the electrode surface goes beyond the boiling point of a working fluid, IEG is getting filled with the vapour-gas mixture that increases both the fraction of idle pulses of discharge current and the probability of a short circuit. In the view of these circumstances, a search for parameters adequately characterizing the efficiency of the EDM process, which can be adjusted to different technological modes, is an important task, the solution of which will make a great contribution to the accuracy and productivity of technologies using electrical erosion processes
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