The benefits of using instantaneous energy to monitor the transient state of the wire EDM process

Abstract

This paper deals with the implementation and analysis of real-time energy monitoring of the transient state of the wire electrical discharge machining (WEDM) process. Recently, sparking frequency information has been applied to control of the WEDM process, making more stable and efficient machining. Experimental results, however, show the limitations and insufficiency of that method. Instead of using the sparking frequency monitoring method, the use of a real-time instantaneous energy monitoring system is suggested for interpreting the state of the WEDM process in more precise detail. The transient state of the WEDM process is analyzed in detail with the developed system, and a transient stability criterion of the WEDM process is suggested.

A new tool wear compensation method based on real-time estimation of material removal volume in micro-EDM

“…In this work, delayed discharge is defined as a pulse with peak current lesser than 0.8 times the maximum peak current as it lacks of sufficient charged voltage. This factor is empirically determined through a number of observations and is found to be fairly comparable with voltage decisive factor reported by Kwon and Yang (2006). Weck and Konig (1983) reported that delayed discharge pulse has an insignificant effect on material removal and result in arcs, shorts, and instability of the operation.…”

Evaluation of μEDM-drilling and μEDM-dressing performances based on online monitoring of discharge gap conditions

“…Although effective pulses do not have enough time to evacuate the debris effectively, a considerable amount of current for the corresponding pulses highlights the contribution of these pulses into material removal and hence cannot be discarded completely. Similar kinds of pulses produced from RC circuit μEDM have been shown by Kwon et al [18] and Jahan et al [19] and reported as the pulses that contribute in material removal. Figure 8 also depicts the variation of f p with the depth of machining at two different values of capacitance.…”

A New Pulse Discriminating System for Micro-EDM

“…Delayed discharge is observed to have a peak current lesser than 0.8 maximum peak current as it lacks sufficient charged voltage. This current dividing value is empirically determined through a number of pulse observations from various machining settings and is found to be fairly comparable with voltage dividing values reported by Kwon et al [6]. After the pulse is discriminated, it will be stored to count the number of each pulse type during machining.…”

“…Weck used a combination of voltage ignition delay time and fall time as a pulse differentiating parameter [5]. Voltage peak value discovered by a real-time peak detection algorithm was used to classify the pulses into normal, stable arc, unstable arc, and short circuit [6]. A more detailed pulse differentiating system was developed by Dauw et al [2].…”