Development of a flexible high-speed EDM technology with geometrical transform optimization

The study used Taguchi dynamic approach coupled with a proposed ideal function model to optimize a high-speed EDM process for high geometrical machining precision and accuracy. The designed tool electrode including two basic geometries of square and circle as the distinct characteristics of workpiece is employed to help develop a versatile process for wider industrial applications. To enhance the speed and stability of EDM process, large discharge current is applied and aluminum (Al) powder added into the working fluid throughout the experiments. For robust design of the process parameters, noise factors causing process variation are also included into the experimental design. The experimental error through the analysis of variance (ANOVA) accounted for about 0.521% of the total process variation, indicating a successful experimental design and highly reliable results. It is noted that the energy-related factors, such as pulse duration, duty cycle, and pulsed peak current are responsible for 83.148% of the variation. Additionally, ANOVA reveals that the powder-related factors contribute slightly to the functional variation in the high-speed EDM process. Once the process parameters are optimized, the geometrical variation of the ED machined product is reduced to be 28.48% of the initial conditions and the geometrical accuracy of the product could be adjusted to an ideal value.