Evaluation of the Process Performance in Wire EDM Based on an Online Process Monitoring System

Procedia CIRP, vol. 95, pp. 360–365

Abstract

The wire EDM process can be evaluated according to various criteria. In addition to the generated component quality, the cutting rate is a key performance index for the main cut. Process stability is another evaluation factor. It is defined by a resulting constant feed rate during machining and a low probability of occurrence of wire breakages. In several studies, the discharge distribution has been analyzed to predict a wire breakage. Due to the high discharge frequency, the analysis of the electrical signals has been conducted only for very short time periods. A quantitative evaluation of the continuous wire EDM process could therefore not be carried out. By implementing a real time process monitoring system, the detection of single discharges and the allocation to normal and abnormal discharges can be conducted. By using a FPGA (Field Programmable Gate Array), the characteristic discharge parameters can be analyzed in real time. The monitoring system stores only characteristic numbers and thus a continuous process can be recorded without generating a large data volume.

Authors 5

1. Ugur Küpper corresponding Aachen Laboratory for Machine Tools and Production Engineering (WZL)

   RWTH Aachen University

   Affiliation as printed

   Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University, Campus-Boulevard 30, Aachen 52074, Germany

2. Tim Herrig Aachen Laboratory for Machine Tools and Production Engineering (WZL)

   RWTH Aachen University

   Affiliation as printed

   Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University, Campus-Boulevard 30, Aachen 52074, Germany

3. A. Klink Aachen Laboratory for Machine Tools and Production Engineering (WZL)

   RWTH Aachen University

   Affiliation as printed

   Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University, Campus-Boulevard 30, Aachen 52074, Germany

4. David Welling
   Affiliation as printed

   Makino Europe GmbH, Karl-Friedrich-Straße 60, Aachen 52072, Germany

5. Thomas Bergs Aachen Laboratory for Machine Tools and Production Engineering (WZL)

   RWTH Aachen University

   Affiliation as printed

   Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University, Campus-Boulevard 30, Aachen 52074, Germany