Prediction and analysis of EDM performances considering random multiple-pulse discharges based on geometric optimization modeling

Continuous electrical discharge machining (EDM) is characterized by random positions, uncertain energy, extremely short time, narrow tool-workpiece gaps, etc. Theoretical research into the mechanisms leading to thermal erosion of material and associated surface morphology has become urgent allow continued development application EDM technology. Firstly, multi-pulse theory geometric optimization are utilized derive an expression for removal rate roughness in EDM. Secondly, based on characteristics discharge, a numerical simulation model was established predict volume, roughness, thickness recast layer. Finally, results predicted models compared with experimental results. Experimentally, 0.176 mg removed EDM; theoretical calculation same produce errors 5.11% 11.36%, respectively. The analogous 1.623 μm, 8.93%, 1.23%. experimentally determined layer 5.31 which corresponds error 7.53%.