Data Dependent Systems Approach to EDM Process Modeling from Surface Roughness Profiles

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The presence of stochastic as well as deterministic processes during electro-discharge machining has been recognized. This paper applies a recently developed methodology called Data Dependent Systems to bridge the gap between the single discharge approach and the time-averaged approach by defining and obtaining a "characteristic crater" from EDMed surface profiles. The characteristic crater accounts for the randomness in the process and includes the effect of mutual interactions and successive dependencies within a train of discharges in the practical domain of electro-discharge machining. Therefore the erosion rate calculations based on the characteristic crater provide a better ouantitative agreement with experimental results than those based upon the repetition of deterministically derived or even measured results of single discharges. The validity of such an approach is also tested by applying it to the existing experimental and theoretical work. It is further shown that the characteristic crater compares well with the results obtained from the transient temperature fields of thermal models reported in the literature. The possibility of describing other features of surface integrity such as heat affected zone, microcracks, residual stresses, etc. through the characteristic crater and related parameters is also discussed. © 1980 CIRP.

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CIRP Annals - Manufacturing Technology