Minimum-variance self-tuning regulator in EDM drilling processes for ultra-high-aspect-ratio small holes
High speed small hole electrical discharge machining (EDM) drilling processes can easily become unstable, due to changing flushing conditions, inappropriate preset electrical parameters, and machining debris residues. Although there are already successful attempts in controlling EDM processes, cost-...
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| Veröffentlicht in: | International journal of advanced manufacturing technology 2020-12, Vol.111 (11-12), p.3293-3303 |
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| container_issue | 11-12 |
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| container_title | International journal of advanced manufacturing technology |
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| creator | Xi, Xue-Cheng Ye, Long Yu, Jian-Hua Zhao, Wan-Sheng |
| description | High speed small hole electrical discharge machining (EDM) drilling processes can easily become unstable, due to changing flushing conditions, inappropriate preset electrical parameters, and machining debris residues. Although there are already successful attempts in controlling EDM processes, cost-effective adaptive control of high speed small hole EDM drilling has not been reported. Process stability can contribute to the improvement of machining efficiency and surface finish. To maintain a higher process stability, a minimum-variance self-tuning regulator (MVSTR) is designed based on an auto-regressive moving average exogenous (ARMAX) model. To determine specifications of the system, the time and frequency responses are analyzed, and the validation is executed for the offline system model. A series of high aspect ratio holes drilling experiments with different electrode diameters of 0.3 mm, 1.0 mm, and 3.0 mm show that, with the use of the MVSTR control scheme, a higher machining efficiency and a lower tool wear can be achieved as compared with the original controller. Microscopic pictures of drilled holes and electrodes show better surface quality. |
| doi_str_mv | 10.1007/s00170-020-06285-8 |
| format | Article |
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Although there are already successful attempts in controlling EDM processes, cost-effective adaptive control of high speed small hole EDM drilling has not been reported. Process stability can contribute to the improvement of machining efficiency and surface finish. To maintain a higher process stability, a minimum-variance self-tuning regulator (MVSTR) is designed based on an auto-regressive moving average exogenous (ARMAX) model. To determine specifications of the system, the time and frequency responses are analyzed, and the validation is executed for the offline system model. A series of high aspect ratio holes drilling experiments with different electrode diameters of 0.3 mm, 1.0 mm, and 3.0 mm show that, with the use of the MVSTR control scheme, a higher machining efficiency and a lower tool wear can be achieved as compared with the original controller. 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Although there are already successful attempts in controlling EDM processes, cost-effective adaptive control of high speed small hole EDM drilling has not been reported. Process stability can contribute to the improvement of machining efficiency and surface finish. To maintain a higher process stability, a minimum-variance self-tuning regulator (MVSTR) is designed based on an auto-regressive moving average exogenous (ARMAX) model. To determine specifications of the system, the time and frequency responses are analyzed, and the validation is executed for the offline system model. A series of high aspect ratio holes drilling experiments with different electrode diameters of 0.3 mm, 1.0 mm, and 3.0 mm show that, with the use of the MVSTR control scheme, a higher machining efficiency and a lower tool wear can be achieved as compared with the original controller. Microscopic pictures of drilled holes and electrodes show better surface quality.</description><subject>Adaptive control</subject><subject>Autoregressive moving average</subject><subject>Autoregressive moving-average models</subject><subject>CAE) and Design</subject><subject>Computer-Aided Engineering (CAD</subject><subject>Drilling</subject><subject>EDM electrodes</subject><subject>Electric discharge machining</subject><subject>Engineering</subject><subject>Frequency analysis</subject><subject>High aspect ratio</subject><subject>High speed</subject><subject>Industrial and Production Engineering</subject><subject>Mechanical Engineering</subject><subject>Media Management</subject><subject>Original Article</subject><subject>Regression analysis</subject><subject>Self tuning</subject><subject>Surface finish</subject><subject>Surface properties</subject><subject>Tool wear</subject><issn>0268-3768</issn><issn>1433-3015</issn><fulltext>true</fulltext><rsrctype>article</rsrctype><creationdate>2020</creationdate><recordtype>article</recordtype><sourceid>AFKRA</sourceid><sourceid>BENPR</sourceid><sourceid>CCPQU</sourceid><sourceid>DWQXO</sourceid><recordid>eNp9kEtPxCAUhYnRxDr6B1yRuEahtDyWZhwfyUzc6JpQSlsmtB2hNfHfy1gTdy5uWJzvnHs5AFwTfEsw5ncRY8IxwnkalosSiROQkYJSRDEpT0GGcyYQ5Uycg4sY9wlnhIkMdDs3uH7u0acOTg_Gwmh9g6Z5cEMLg21nr6cxQDfAzcMO1sF5f1QOYTQ2Rhthk9TZT0GjzrUd0vFgzYSCntwIY6-9h93obbwEZ4320V79vivw_rh5Wz-j7evTy_p-iwwlckKU2JJIbkzTSFpLXRGiBa5kJSmtS17WlZS4lrwwkhldNtjUVZFEzmWdfm_pCtwsuenCj9nGSe3HOQxppcoLiYWkmLFE5QtlwhhjsI06BNfr8KUIVsdG1dKoSpnqp1ElkokuppjgobXhL_of1zede3pR</recordid><startdate>20201201</startdate><enddate>20201201</enddate><creator>Xi, Xue-Cheng</creator><creator>Ye, Long</creator><creator>Yu, Jian-Hua</creator><creator>Zhao, Wan-Sheng</creator><general>Springer London</general><general>Springer Nature B.V</general><scope>AAYXX</scope><scope>CITATION</scope><scope>8FE</scope><scope>8FG</scope><scope>ABJCF</scope><scope>AFKRA</scope><scope>BENPR</scope><scope>BGLVJ</scope><scope>CCPQU</scope><scope>DWQXO</scope><scope>HCIFZ</scope><scope>L6V</scope><scope>M7S</scope><scope>PQEST</scope><scope>PQQKQ</scope><scope>PQUKI</scope><scope>PRINS</scope><scope>PTHSS</scope></search><sort><creationdate>20201201</creationdate><title>Minimum-variance self-tuning regulator in EDM drilling processes for ultra-high-aspect-ratio small holes</title><author>Xi, Xue-Cheng ; 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| subjects | Adaptive control Autoregressive moving average Autoregressive moving-average models CAE) and Design Computer-Aided Engineering (CAD Drilling EDM electrodes Electric discharge machining Engineering Frequency analysis High aspect ratio High speed Industrial and Production Engineering Mechanical Engineering Media Management Original Article Regression analysis Self tuning Surface finish Surface properties Tool wear |
| title | Minimum-variance self-tuning regulator in EDM drilling processes for ultra-high-aspect-ratio small holes |
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