High efficient electrical discharge machining processes based upon linear motors and pulses discriminator feedback

A novel direct-driven electrical discharge machining (EDM) based upon linear motors and a machining feedback by pulses discriminator was proposed. Conventional EDM allowed only fixed setting of jump parameters, which wasted lots of effective working time. An effective pulse discriminator was developed to detect gap status under direct-drive EDM situation. By introducing this pulses discriminator, an adjustable EDM jump control associated with this feedback removal information was proposed. It is evident from experiments that this discriminator is effective and such a jump controller is more efficient than traditional one. For example, its machining speed is risen up to 3.5 times compared to conventional one in aspect ratio of 17.5 deep EDM platelet processing. Its surface integrity and more uniform gap width are also improved significantly, resulted from better debris expelling than conventional EDM flushing processes.