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Minimum-variance self-tuning regulator in EDM drilling processes for ultra-high-aspect-ratio small holes

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Abstract

High speed small hole electrical discharge machining (EDM) drilling processes can easily become unstable, due to changing flushing conditions, inappropriate preset electrical parameters, and machining debris residues. Although there are already successful attempts in controlling EDM processes, cost-effective adaptive control of high speed small hole EDM drilling has not been reported. Process stability can contribute to the improvement of machining efficiency and surface finish. To maintain a higher process stability, a minimum-variance self-tuning regulator (MVSTR) is designed based on an auto-regressive moving average exogenous (ARMAX) model. To determine specifications of the system, the time and frequency responses are analyzed, and the validation is executed for the offline system model. A series of high aspect ratio holes drilling experiments with different electrode diameters of 0.3 mm, 1.0 mm, and 3.0 mm show that, with the use of the MVSTR control scheme, a higher machining efficiency and a lower tool wear can be achieved as compared with the original controller. Microscopic pictures of drilled holes and electrodes show better surface quality.

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Funding

This research is financially supported by National Science and Technology Major Project of China (No. 2018ZX04005001), National Natural Science Foundation of China (No. 51675340), Shenzhen Basic Research Program (Grant No. JCYJ20170811160440239).

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Authors and Affiliations

  1. Shenzhen Research Institute, State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, China

    Xue-Cheng Xi

  2. Department of Mechanical Engineering, KU Leuven, Leuven, Belgium

    Long Ye

  3. AECC Commercial Aircraft Engine Co., Ltd, Shanghai, China

    Jian-Hua Yu

  4. State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, China

    Wan-Sheng Zhao

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  1. Xue-Cheng Xi
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  2. Long Ye
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  3. Jian-Hua Yu
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  4. Wan-Sheng Zhao
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Correspondence to Xue-Cheng Xi.

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Xi, XC., Ye, L., Yu, JH. et al. Minimum-variance self-tuning regulator in EDM drilling processes for ultra-high-aspect-ratio small holes. Int J Adv Manuf Technol 111, 3293–3303 (2020). https://doi.org/10.1007/s00170-020-06285-8

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  • DOI: https://doi.org/10.1007/s00170-020-06285-8

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