Electrode wear performance during electrical discharge machining (EDM) using machine vision

In this work, the wear performance of two different EDM electrode materials i.e. copper (100%) and copper/nickel (90:10) is investigated when machining aluminium alloy (Al6061) by utilising machine vision monitoring technique. The fundamental phenomenon of electrode wear typically occurs as anode di...

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Bibliographic Details
Main Authors: Sani, Amiril Sahab Abdul, Zabidi, Azlee, Abu, Mohd Yazid
Format: Conference Proceeding
Language:English
Subjects:
Algorithms
Aluminum base alloys
Copper
Die sinking
Disintegration
EDM electrodes
Electric discharge machining
Electrode materials
Electrodes
Machine vision
Machinery condition monitoring
Mathematical analysis
Nickel
Vision systems
Wear rate
Workpieces
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Summary:In this work, the wear performance of two different EDM electrode materials i.e. copper (100%) and copper/nickel (90:10) is investigated when machining aluminium alloy (Al6061) by utilising machine vision monitoring technique. The fundamental phenomenon of electrode wear typically occurs as anode disintegration can have impact to the surface integrity of both the tool and workpiece. However, there are relatively few studies on the assessment of electrode wear rate (EWR) of different materials using machine vision. By comparing the progressive wear of the electrode during the machining process, the available data of EWR is used as reference to measure the degree of abnormal observation between the conventional optical monitoring and machine vision methodology. EWR can be calculated by measuring the average rate of the degraded electrode and the machining time. The weight of the electrode after EDM is used to calculate wear by comparing it to the initial weight of the electrodes since weighing the electrode during the in-process treatment is quite tricky. As to this, a tool condition monitoring system algorithm was studied to be developed using machine vision to predict the progression of electrode wear. From the results, the degree of abnormality was successfully measured using the MATLAB algorithm. The acquired result indicates that the copper/nickel electrode is a weak element to undergo EDM die-sinking process compared to copper when machining aluminium, whereby the percentage of electrode wear between copper and copper/nickel electrodes in the fifth pass shows that copper is more than 99% slower to be worn out.
ISSN:0094-243X
1551-7616
DOI:10.1063/5.0114665