Machine Learning-Driven Approach for Reducing Tool Wear in Die-Sinking Electrical Discharge Machining

Abstract

This study examines the use of machine learning (ML) techniques to optimize the basic machining parameters and protrusion dimensions that affect tool shape degeneration in die-sinking electric discharge machining (EDM). The primary objective is to decrease errors and enhance prediction and optimization effectiveness. This study introduces a completely novel tool geometry model aimed at minimizing tool shape degeneration, which, to our knowledge, has not been previously documented in the literature. Additionally, this research represents the first instance of employing ML techniques to generate data for addressing this specific type of problem, further advancing the field of die-sinking EDM. The pivotal machining parameters include discharge current, pulse time and machining depth. Three ML approaches are implemented in this investigation: Artificial Neural Network (ANN), Adaptive-Network-Based Fuzzy Inference System (ANFIS), and Support Vector Machine (SVM). In comparison with experimental outcomes, the ANN technique exhibited superior predictive ability with an coefficient of determination (R2) of 0.99985 and an Mean Relative Error (MRE) of 0.854%. Four distinct EDM machining scenarios are presented and machining parameters and protrusion dimensions are optimized using the ANN technique to decrease tool shape degeneration. Optimizing the machining parameters and diagonal dimensions of the protrusion substantially reduced tool shape degeneration. This research demonstrates the effectiveness of ANN in optimizing machining parameters and improving tool performance in die-sinking EDM. A significant reduction in total wear area of 66.7% was achieved with a considerably lower time cost through the optimized ANN network. While the study demonstrates promising results, its reliance on specific datasets for training may limit the generalizability of the model to broader machining scenarios.