SpringerLink
Log in

A study on electrode wear sensing and compensation in Micro-EDM using machine vision system

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

This paper presents an electrode wear compensation method based on a machine vision system for micro-electro-discharge machining (EDM). Front wear and corner wear of tool electrode can be measured and evaluated in a direct manner by the vision system’s image-processing software capabilities. Tool electrode images have depicted that the front wear and corner wear were increased rapidly during EDM drilling and EDM milling, respectively, and thus contributing to an arc and a tapering shape at the end of tool electrode, respectively. Both the depth of the hole and depth of the groove are linearly proportional to the length of the front wear. A new electrode wear compensation method is presented based on the direct measurement of the front wear. Experimental results not only verify the usefulness of the electrode wear compensation method in micro-EDM, they also demonstrate that the machining time can be significantly reduced by 40% when using the proposed method, compared to the uniform wear method.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Subscribe and save

Springer+ Basic
EUR 32.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or Ebook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Masuzawa T (2000) State of art of micromachining. CIRP Ann 49(2):473–488

    Article  Google Scholar 

  2. Yu ZY, Masuzawa T, Fujiino M (1998) Micro-EDM for three-dimensional cavities—development of uniform wear method. CIRP Ann 47(1):169–172

    Article  Google Scholar 

  3. Yu ZY, Masuzawa T, Fujiino M (1998) 3D micro-EDM with simple shape electrode. Part 1. Int J Electr Mach 3:7–12

    Google Scholar 

  4. Yu ZY, Masuzawa T, Fujiino M (1998) 3D micro-EDM with simple shape electrode. Part 2. Int J Electr Mach 3:71–79

    Google Scholar 

  5. Rajurkar KP, Yu ZY (2000) 3D micro-EDM using CAD/CAM. CIRP Ann 49(1):127–130

    Article  Google Scholar 

  6. Yu ZY, Kozak J, Rajurkar KP (2003) Modelling and simulation of micro EDM process. CIRP Ann 52(1):143–146

    Article  Google Scholar 

  7. Bleys P, Kruth JP, Lauwers B (2004) Sensing and compensation of tool wear in milling EDM. J Mater Process Technol 149(1–3):139–146 doi:10.1016/j.jmatprotec.2003.11.042

    Article  Google Scholar 

  8. Bleys P, Kruth JP, Lauwers B, Zryd A, Delpretti R, Tricarico C (2002) Real time tool wear compensation in milling EDM. CIRP Ann 51(1):157–160

    Article  Google Scholar 

  9. Jeong YH, Min B-K (2007) Geometry prediction of EDM-drilled holes and tool electrode shapes of micro-EDM process using simulation. Int J Mach Tools Manuf 47(5):1817–1826 doi:10.1016/j.ijmachtools.2007.04.011

    Article  Google Scholar 

  10. Kozak J, Ivanov A, Al-naemi F, Gulbinowicz Z (2007) EDM electrode wear and its effect on processes accuracy and process modeling. In: Proceedings of the 15th International Symposium on Electromachining (ISEM-15), pp 81–86

  11. Sato T, Imai Y, Goto A, Magara T (2000) A new grooving method based on steady wear model in EDM. Int J Electr Machining 5:41–49

    Google Scholar 

  12. Pham DT, Ivanov A, Bigot S, Popov K, Dimov S (2007) An investigation of tube and rod electrode wear in micro EDM drilling. Int J Adv Manuf Technol 33(1–2):103–109 doi:10.1007/s00170-006-0639-7

    Article  Google Scholar 

  13. Chang YF, Chiu ZH (2004) Electrode wear-compensation of electric discharge scanning process using a robust gap-control. Mechatronics 14:1121–1139 doi:10.1016/j.mechatronics.2004.06.005

    Article  Google Scholar 

  14. Li Y, Hao T, Yang W (2007) Servo scanning process of 3D micro EDM. In: Proceedings of Asian Electrical Machining Symposium ‘07, Nagoya, Japan, 28–30 November, pp 198–202

  15. Hao T, Yang W, Li Y (2008) Vibration-assisted servo scanning process 3D micro EDM. J Micromech Microeng 18:1–8 doi:10.1088/0960-1317/18/2/025011

    Article  Google Scholar 

  16. Ozgedik A, Cogun C (2006) An experimental investigation of tool wear in electric discharge machining. Int J Adv Manuf Technol 27(5–6):488–500 doi:10.1007/s00170-004-2220-6

    Article  Google Scholar 

  17. Kaneko T, Tsuchiya M, Kazama A (1992) Improvement of 3D NC contouring EDM using cylindrical electrodes-optical measurement of electrode deformation and machining of free-curves. In: Proceedings of the 10th International Symposium for Electromachining (ISEM X), pp 364–367

  18. Guo R, Zhao WS, Li G, Li Z, Zhang Y (2007) A Linux based CNC system for micro electrical machining. In: Proceedings of the 15th International Symposium on Electromachining (ISEM XV), pp 603–607

  19. Yan MT, Chen WJ, Lo CY, Huang KY (2007) Development of an open architecture CNC system for micro-EDM. Proceedings of Asian Electrical Machining Symposium ‘07, Nagoya, Japan, 28–30 November, pp 258–263

Download references

Author information

Authors and Affiliations

  1. Department of Mechatronic Engineering, Huafan University, No. 1, Huafan Rd., Shihtin Hsiang, 223, Taipei Hsien, Taiwan, Republic of China

    Mu-Tian Yan, Kuo-Yi Huang & Chin-Yen Lo

Authors
  1. Mu-Tian Yan
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Kuo-Yi Huang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Chin-Yen Lo
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Mu-Tian Yan.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Yan, MT., Huang, KY. & Lo, CY. A study on electrode wear sensing and compensation in Micro-EDM using machine vision system. Int J Adv Manuf Technol 42, 1065–1073 (2009). https://doi.org/10.1007/s00170-008-1674-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-008-1674-3

Keywords

Search

Navigation