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Technical Briefs

Fuzzy Logic Control of Microhole Electrical Discharge Machining

[+] Author and Article Information
Chen-Chun Kao, Albert J. Shih

Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109

Scott F. Miller

Mechanical Engineering, University of Hawaii, Honolulu, HI 96822

J. Manuf. Sci. Eng 130(6), 064502 (Oct 10, 2008) (6 pages) doi:10.1115/1.2977827 History: Received July 04, 2007; Revised July 21, 2008; Published October 10, 2008

A microhole electrical discharge machining (EDM) system with adaptive fuzzy logic control and precision piezoelectric stage is developed in this study. A high-speed EDM monitoring system is implemented to measure the gap voltage, current, and ignition delay time, which are used to derive three input parameters—the average gap voltage, deviation in spark ratio, and change in the deviation in spark ratio—for the fuzzy logic control. Servo displacement and speed of the piezoelectric stage during each sampling duration are synthesized in real time by the adaptive fuzzy logic controller. Effects of the single and multiple input parameters, ignition delay threshold value, and maximum servo displacement and speed on the EDM drilling process are experimentally studied. Experimental results show that the fuzzy logic EDM control system yields a much more stable and efficient microhole EDM drilling process.

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Copyright © 2008 by American Society of Mechanical Engineers
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Figures

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Figure 1

The microhole EDM

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Figure 2

Configuration of the fuzzy logic microhole EDM control system

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Figure 3

Measured voltage and current and corresponding parameters in a 1ms sampling duration T

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Figure 4

Schematic diagram of the adaptive fuzzy logic controller

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Figure 5

Membership functions for fuzzy logic parameters: (a) ΔRs and δ(ΔRs), (b) v, and (c) d

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Figure 6

Classification of EDM pulses by ignition delay td

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Figure 7

Gap voltage and current of the EDM pulse train: (a) no fuzzy logic control applied and (b) with the fuzzy logic EDM control (three-input type, dmax=2μm, vmax=1.8mm∕s, and tdt=80μs)

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Figure 8

Arc pulses and drilling time under different tdt (three-input type, dmax=2μm, vmax=1.8mm∕s)

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Figure 9

Movements of piezoelectric stage under three levels of dmax=2μm, 4μm, and 8μm (three-input type, vmax=1.8mm∕s, and tdt=80μs)

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Figure 10

Experimental results of the fuzzy logic EDM control (three-input type, dmax=2μm, vmax=1.8mm∕s, and tdt=62.5μs)

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