Modeling and Control of Electro Discharge Machining for Machining of Advanced Materials and Complex Shapes

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This research effort is designed to develop an Electro Discharge Machining (EDM) technology data base for hard to machine, brittle materials and develop an on-line monitoring and control scheme for process optimization based on standard statistical and neural network approaches. This will enable the efficient machining of complex contours in materials such as polycrystalline diamond (PCD) and conductive ceramics. Since the EDM process is complex and random due to transient dielectric flow conditions and distribution of debris, deterministic and stochastic modelling and analysis will be utilized to understand the process and to develop quantitative models for the material removal rates, arcing and wire rupture. This research is very timely in the sense that utilization of hard materials for a variety of industrial processes is on an increase. The ability to monitor and optimize the EDM process will have a significant impact on the efficiency and productivity of industry.