Development of a Process Evaluation System for Wire-EDM Applications Using an Intelligent Process Monitoring Tool

In this paper a first approach is presented to investigate the electrical parameters of the EDM process using an intelligent process monitoring tool to evaluate different technologies and generators. Goal is to characterize every single discharge by extracting relevant data from recorded current and voltage signals using an adequate algorithm. For demonstration purposes a steel material is machined using a corresponding technology recommended by the machine tool supplier as well as a recommended technology for hard metal. In a first step the machining quality is evaluated by the cutting rate and surface roughness which is common practice for EDM. These results are then compared to the data extracted by the process monitoring tool. In the future this tool may be able to accelerate the parameter development for a specific task or material significantly. The effectiveness of the process could be determined directly during the process and no longer indirectly by a quality inspection of the machined part. By investigating the course of each discharge the process parameters can be linked to the actual physical parameters and a direct influence could be identified.