A new adaptive control strategy for EDM of high aspect ratio holes

The processing of high-aspect-ratio holes using Electrical Discharge Machining (EDM) technology presents several challenges, including electrode wear, debris removal issues, and diminished processing efficiency. To address these issues, this study introduces a novel adaptive control strategy that incorporates adaptive servo motion control based on fuzzy theory and cleaning pulses. This control strategy employs adaptive servo motion control for precise and efficient positioning, while cleaning pulses help remove debris from the inter-electrode gap. With this strategy, the electrode feed rate increased by approximately 1.5 times compared to the original control, within the same duration. This approach resulted in a 22% reduction in processing time and an 11% reduction in electrode wear when machining nickel-based alloy workpieces. The experimental results confirm that the adaptive control strategy substantially enhances the process stability of high -aspect-ratio holes and improves machining efficiency.