Modelling the manufacturing parameters in electrical discharge machining for on-line quality control

The correct selection of production conditions is crucial in processes related to electrical discharge machining (EDM) of conductive materials, as these conditions significantly influence the surface roughness of the machined workpiece. This study employs a Design of Experiment (DOE) approach to investigate the impact of various factors, including peak current generated by the EDM generator, servosensitivity, and sparking gap, on key technological characteristics. Using copper as the electrode material and mild steel as the workpiece, a series of mathematical models are developed through the DOE technique. This enables the identification of optimal machining conditions for achieving desired surface finish with a minimal number of experiments. Additionally, this research explores the potential of using sound waves generated during machining, particularly the acoustic signals from sparks, to analyze the effects of process parameters. The findings indicate a promising avenue for enhancing on-line quality control in EDM, although the relationship between acoustic emissions and machining quality is complex and warrants further investigation.