Dynamic mathematical model for low power electrical discharge machining applications

Abstract

Electrical discharge machining is one of the widely used machining methods, principally in medical applications, aerospace industry and manufacturing in hard material fields. However, scientific knowledge about the process is still insufficient for its more improvements. Experimental work are time consuming and costly due to the complex and stochastic character of the EDM procedure. Process modeling is a great option in order to reduce the experimental difficulty related to the technology. This paper presents a dynamic mathematical model for low power EDM application. The propounded model includes the precise insight into the interactive behavior of EDM system based on the sparking phases and pulse power generator. The ignition, discharge and recovery phases of the model have been developed through MATLAB's time domain analysis. Contributions are contrived in different aspects of the entire system, containing modeling and system simulation. The result shows expected profiles with satisfactory dynamic performance. To verify the model, simulated material removal rates (MRRs) are obtained using machining parameters from series of simulation and then compared with the experimental ones carried out by previous researcher. Ability of the model to predict the dynamic behavior profile of the EDM system is successfully confirmed by low average percentage error in predicting MRR.