Optimum Material Removal in Electrical Discharge Machining through Advanced Control Integration of PSoC Microcontroller
Electrical Discharge Machining (EDM) is an advanced non-traditional method for precision material removal using repeated electrical discharges. It utilizes a programmable tool electrode to intricately shape designs. Existing research has highlighted that current EDM control systems are often intri...
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| Main Authors: | , , , , , |
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| Format: | Article |
| Language: | en |
| Published: |
Penerbit Universiti Kebangsaan Malaysia
2025
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| Online Access: | http://journalarticle.ukm.my/26742/1/01.pdf http://journalarticle.ukm.my/26742/ https://www.ukm.my/jkukm/volume-3701-2025/ |
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| Summary: | Electrical Discharge Machining (EDM) is an advanced non-traditional method for precision material removal using
repeated electrical discharges. It utilizes a programmable tool electrode to intricately shape designs. Existing
research has highlighted that current EDM control systems are often intricate, sluggish, and costly. In addressing
these limitations, there is a notable opportunity to enhance the design of an advanced EDM control system, that is
both sophisticated and cost-eff ective. Therefore, the authors proposed an integration of a pulse generator, control
system, timer, and fl ushing system using a Programmable System-on-Chip (PSoC) microcontroller to regulate the gap
between an electrode a workpiece, fl ushing system, and the overall EDM machining process. The pulse generator
algorithm was developed to effi ciently manage Ton and Toff , while the Proportional Integral Derivative (PID) algorithm
was employed to uphold the gap between the electrode and the workpiece. Additionally, the timer algorithm was
closely associated with the machining process timing. Activation of the second servo pump at 80% of machining was
implemented to enhance the fl ushing pressure rate. The EDM-PSoC system was utilized with the experiment
conduction at three diff erent current settings (2A, 4A, and 6A) over fi ve periods, and results were compared with the
EDM-Existing system. The experimental outcomes revealed a notable increase in Material Removal Rate (MRR),
averaging 0.1348 mm3/min at 6A. Furthermore, the EDM-PSoC system demonstrated high consistency in each
repetition experiment conducted at lower currents, achieving MRRs of 0.0142 mm3/min at 2A and 0.0560 mm3/min at
4A. Comparatively, the EDM-PSoC system improved the average MRR by 49% compared to the traditional EDMExisting
system. The depth of the machined workpiece produced by the EDM-PSoC system was deeper than the EDMExisting
system at equivalent time settings. Consequently, the fi ndings indicate that the EDM-PSoC system achieved a
higher MRR relative to the conventional EDM procedure, thus improving signifi cantly the system effi ciency. |
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