Modeling of the effect of tool wear per discharge estimation error on the depth of machined cavities in micro-EDM milling

Govindan Puthumana; Giuliano Bissacco; Hans Nørgaard Hansen

doi:10.1007/s00170-017-0371-5

Modeling of the effect of tool wear per discharge estimation error on the depth of machined cavities in micro-EDM milling

Govindan Puthumana, Giuliano Bissacco, Hans Nørgaard Hansen

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Abstract

In micro-EDM milling, real time electrode wear compensation based on tool wear per discharge (TWD) estimation permits the direct control of the position of the tool electrode frontal surface. However, TWD estimation errors will cause errors on the tool electrode axial depth. A simulation tool is developed to determine the effects of errors in the initial estimation of TWD and its propagation effect with respect to the error on the depth of the cavity generated. Simulations were applied to micro-EDM milling of a slot of 5000 μm length and 50 μm depth and validated through slot milling experiments performed on a micro-EDM machine. Simulations and experimental results were found to be in good agreement, showing the effect of errror amplification through the cavity depth.

Original language	English
Journal	International Journal of Advanced Manufacturing Technology
Volume	92
Issue number	9-12
Pages (from-to)	3253-3264
ISSN	0268-3768
DOIs	https://doi.org/10.1007/s00170-017-0371-5
Publication status	Published - 2017

Keywords

EDM
Precision machining
Tool electrode wear
Simulation
Depth error
Error propagation

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10.1007/s00170-017-0371-5

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COFUNDPostdocDTU: COFUNDPostdocDTU
Præstrud, M. R. (Project Participant) & Brodersen, S. W. (Project Participant)
01/01/2014 → 31/12/2019
Project: Research

Cite this

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title = "Modeling of the effect of tool wear per discharge estimation error on the depth of machined cavities in micro-EDM milling",

abstract = "In micro-EDM milling, real time electrode wear compensation based on tool wear per discharge (TWD) estimation permits the direct control of the position of the tool electrode frontal surface. However, TWD estimation errors will cause errors on the tool electrode axial depth. A simulation tool is developed to determine the effects of errors in the initial estimation of TWD and its propagation effect with respect to the error on the depth of the cavity generated. Simulations were applied to micro-EDM milling of a slot of 5000 μm length and 50 μm depth and validated through slot milling experiments performed on a micro-EDM machine. Simulations and experimental results were found to be in good agreement, showing the effect of errror amplification through the cavity depth.",

keywords = "EDM, Precision machining, Tool electrode wear, Simulation, Depth error, Error propagation",

author = "Govindan Puthumana and Giuliano Bissacco and Hansen, {Hans N{\o}rgaard}",

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volume = "92",

pages = "3253--3264",

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Modeling of the effect of tool wear per discharge estimation error on the depth of machined cavities in micro-EDM milling. / Puthumana, Govindan; Bissacco, Giuliano ; Hansen, Hans Nørgaard.
In: International Journal of Advanced Manufacturing Technology, Vol. 92, No. 9-12, 2017, p. 3253-3264.

Research output: Contribution to journal › Journal article › Research › peer-review

TY - JOUR

T1 - Modeling of the effect of tool wear per discharge estimation error on the depth of machined cavities in micro-EDM milling

AU - Puthumana, Govindan

AU - Bissacco, Giuliano

AU - Hansen, Hans Nørgaard

PY - 2017

Y1 - 2017

N2 - In micro-EDM milling, real time electrode wear compensation based on tool wear per discharge (TWD) estimation permits the direct control of the position of the tool electrode frontal surface. However, TWD estimation errors will cause errors on the tool electrode axial depth. A simulation tool is developed to determine the effects of errors in the initial estimation of TWD and its propagation effect with respect to the error on the depth of the cavity generated. Simulations were applied to micro-EDM milling of a slot of 5000 μm length and 50 μm depth and validated through slot milling experiments performed on a micro-EDM machine. Simulations and experimental results were found to be in good agreement, showing the effect of errror amplification through the cavity depth.

AB - In micro-EDM milling, real time electrode wear compensation based on tool wear per discharge (TWD) estimation permits the direct control of the position of the tool electrode frontal surface. However, TWD estimation errors will cause errors on the tool electrode axial depth. A simulation tool is developed to determine the effects of errors in the initial estimation of TWD and its propagation effect with respect to the error on the depth of the cavity generated. Simulations were applied to micro-EDM milling of a slot of 5000 μm length and 50 μm depth and validated through slot milling experiments performed on a micro-EDM machine. Simulations and experimental results were found to be in good agreement, showing the effect of errror amplification through the cavity depth.

KW - EDM

KW - Precision machining

KW - Tool electrode wear

KW - Simulation

KW - Depth error

KW - Error propagation

U2 - 10.1007/s00170-017-0371-5

DO - 10.1007/s00170-017-0371-5

M3 - Journal article

SN - 0268-3768

VL - 92

SP - 3253

EP - 3264

JO - International Journal of Advanced Manufacturing Technology

JF - International Journal of Advanced Manufacturing Technology

IS - 9-12

ER -

Modeling of the effect of tool wear per discharge estimation error on the depth of machined cavities in micro-EDM milling

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