Knowledge based design of EDM electrodes for mould cavities pre-machined by high-speed milling

Electric discharge machining (EDM) electrode design has always been an important activity in the die and mould making sector. Nowadays, software’s are available to design electrodes. Using software, the EDM specialist has to select the areas in the mould cavity that are to be EDM’ed. Once the areas are selected, a typical software designs an electrode along with its holder. If the mould cavity is very complex, as is the case when the mould cavity is pre-machined by high-speed milling, the EDM specialist has to think of several possible electrode combinations/designs and to select the best solution. He does this based on his knowledge of EDM and the knowledge of the process capabilities of his EDM machine tool. This paper presents the basic principles of designing a knowledge based system for automated EDM electrode design. This system works with similar logic, that an experienced EDM specialist would use to design electrodes. First the overall methodology to design EDM electrodes automatically is described on the highest level. Then the details of this methodology are explained followed by conclusions.