Digital twin modeling of surface texture generation by the electrical discharge machining process

A digital twin model of the surface texture generated by the electrical discharge machining process is developed in three steps. The finite element method is used to model a crater formed by an individual spark. Subsequently, the single spark data is processed and stored in a form of a data set and used in the third phase to plot the real-time status of the machined surface using live data acquisition, data analysis, and multiple spark simulations. This real-time simulation enables more precise control over the EDM process and accurate prediction of surface roughness, contributing to enhanced surface quality and machining efficiency. The experimental specimen underwent R a value testing at various locations, revealing a close alignment between the measured values and the predicted range provided by the digital twin model