Abstract
In micro-EDM milling, real-time electrode wear compensation based on tool wear per discharge (TWD) estimation permits the direct control of the position of the tool electrode frontal surface. However, TWD estimation errors will cause errors on the tool electrode axial depth. A simulation tool is developed to determine the effects of errors in the initial estimation of TWD and its propagation effect with respect to the error on the depth of the cavity generated. Simulations were applied to micro-EDM milling of a slot of 5000-μm length and 50-μm depth and validated through slot milling experiments performed on a micro-EDM machine. Simulations and experimental results were found to be in good agreement, showing the effect of error amplification through the cavity depth.
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