A study on electrode wear sensing and compensation in Micro-EDM using machine vision system

  • Mu-Tian YanEmail author
  • Kuo-Yi Huang
  • Chin-Yen Lo


This paper presents an electrode wear compensation method based on a machine vision system for micro-electro-discharge machining (EDM). Front wear and corner wear of tool electrode can be measured and evaluated in a direct manner by the vision system’s image-processing software capabilities. Tool electrode images have depicted that the front wear and corner wear were increased rapidly during EDM drilling and EDM milling, respectively, and thus contributing to an arc and a tapering shape at the end of tool electrode, respectively. Both the depth of the hole and depth of the groove are linearly proportional to the length of the front wear. A new electrode wear compensation method is presented based on the direct measurement of the front wear. Experimental results not only verify the usefulness of the electrode wear compensation method in micro-EDM, they also demonstrate that the machining time can be significantly reduced by 40% when using the proposed method, compared to the uniform wear method.


Micro-EDM Electrode wear Machine vision 


  1. 1.
    Masuzawa T (2000) State of art of micromachining. CIRP Ann 49(2):473–488CrossRefGoogle Scholar
  2. 2.
    Yu ZY, Masuzawa T, Fujiino M (1998) Micro-EDM for three-dimensional cavities—development of uniform wear method. CIRP Ann 47(1):169–172CrossRefGoogle Scholar
  3. 3.
    Yu ZY, Masuzawa T, Fujiino M (1998) 3D micro-EDM with simple shape electrode. Part 1. Int J Electr Mach 3:7–12Google Scholar
  4. 4.
    Yu ZY, Masuzawa T, Fujiino M (1998) 3D micro-EDM with simple shape electrode. Part 2. Int J Electr Mach 3:71–79Google Scholar
  5. 5.
    Rajurkar KP, Yu ZY (2000) 3D micro-EDM using CAD/CAM. CIRP Ann 49(1):127–130CrossRefGoogle Scholar
  6. 6.
    Yu ZY, Kozak J, Rajurkar KP (2003) Modelling and simulation of micro EDM process. CIRP Ann 52(1):143–146CrossRefGoogle Scholar
  7. 7.
    Bleys P, Kruth JP, Lauwers B (2004) Sensing and compensation of tool wear in milling EDM. J Mater Process Technol 149(1–3):139–146 doi: 10.1016/j.jmatprotec.2003.11.042 CrossRefGoogle Scholar
  8. 8.
    Bleys P, Kruth JP, Lauwers B, Zryd A, Delpretti R, Tricarico C (2002) Real time tool wear compensation in milling EDM. CIRP Ann 51(1):157–160CrossRefGoogle Scholar
  9. 9.
    Jeong YH, Min B-K (2007) Geometry prediction of EDM-drilled holes and tool electrode shapes of micro-EDM process using simulation. Int J Mach Tools Manuf 47(5):1817–1826 doi: 10.1016/j.ijmachtools.2007.04.011 CrossRefGoogle Scholar
  10. 10.
    Kozak J, Ivanov A, Al-naemi F, Gulbinowicz Z (2007) EDM electrode wear and its effect on processes accuracy and process modeling. In: Proceedings of the 15th International Symposium on Electromachining (ISEM-15), pp 81–86Google Scholar
  11. 11.
    Sato T, Imai Y, Goto A, Magara T (2000) A new grooving method based on steady wear model in EDM. Int J Electr Machining 5:41–49Google Scholar
  12. 12.
    Pham DT, Ivanov A, Bigot S, Popov K, Dimov S (2007) An investigation of tube and rod electrode wear in micro EDM drilling. Int J Adv Manuf Technol 33(1–2):103–109 doi: 10.1007/s00170-006-0639-7 CrossRefGoogle Scholar
  13. 13.
    Chang YF, Chiu ZH (2004) Electrode wear-compensation of electric discharge scanning process using a robust gap-control. Mechatronics 14:1121–1139 doi: 10.1016/j.mechatronics.2004.06.005 CrossRefGoogle Scholar
  14. 14.
    Li Y, Hao T, Yang W (2007) Servo scanning process of 3D micro EDM. In: Proceedings of Asian Electrical Machining Symposium ‘07, Nagoya, Japan, 28–30 November, pp 198–202Google Scholar
  15. 15.
    Hao T, Yang W, Li Y (2008) Vibration-assisted servo scanning process 3D micro EDM. J Micromech Microeng 18:1–8 doi: 10.1088/0960-1317/18/2/025011 CrossRefGoogle Scholar
  16. 16.
    Ozgedik A, Cogun C (2006) An experimental investigation of tool wear in electric discharge machining. Int J Adv Manuf Technol 27(5–6):488–500 doi: 10.1007/s00170-004-2220-6 CrossRefGoogle Scholar
  17. 17.
    Kaneko T, Tsuchiya M, Kazama A (1992) Improvement of 3D NC contouring EDM using cylindrical electrodes-optical measurement of electrode deformation and machining of free-curves. In: Proceedings of the 10th International Symposium for Electromachining (ISEM X), pp 364–367Google Scholar
  18. 18.
    Guo R, Zhao WS, Li G, Li Z, Zhang Y (2007) A Linux based CNC system for micro electrical machining. In: Proceedings of the 15th International Symposium on Electromachining (ISEM XV), pp 603–607Google Scholar
  19. 19.
    Yan MT, Chen WJ, Lo CY, Huang KY (2007) Development of an open architecture CNC system for micro-EDM. Proceedings of Asian Electrical Machining Symposium ‘07, Nagoya, Japan, 28–30 November, pp 258–263Google Scholar

Copyright information

© Springer-Verlag London Limited 2008

Authors and Affiliations

  1. 1.Department of Mechatronic EngineeringHuafan UniversityTaipei HsienRepublic of China

Personalised recommendations