Wire EDM Monitoring for Zero-Defect Manufacturing based on Advanced Sensor Signal Processing

摘要

Wire Electrical Discharge Machining (WEDM) processes are investigated in the perspective of zero-defect manufacturing with the aim to detect the process conditions leading to common defects generated during WEDM, i.e. the occurrence of lines and marks on the resulting surface. The study is performed through the employment of a multiple sensor monitoring system able to acquire voltage and current data in the gap between the workpiece and the wire electrode with a very high sampling rate. An advanced sensor signal processing methodology is proposed and applied to extract the most relevant features that could be help detect abnormal process conditions producing surface defects.