Abstract
This paper reports a WEDM sparking frequency monitor developed to detect the thermal load for on-line control to prevent the wire from rupture. The wire rupture phenomena are also analyzed with a thermal model. An extensive experimental investigation has been carried out to determine the process performances such as machining rate and surface finish with overall control parameters of an ED machine. The relationship between the machining rate and surface finish under optimal machine settings has been determined by means of a multi-objective model.
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