Prediction of contour deviation in wire EDM using continuously processed electrical process signals

Wire Electrical Discharge Machining (WEDM) is a precise manufacturing process that relies on controlled electrical discharges between a wire electrode and a workpiece to cut complex contours. However, variations in process conditions, such as changes in the working gap, can lead to deviations in contour accuracy, compromising shape tolerances. This study presents a data-driven model to predict contour deviations in WEDM using electrical process parameters recorded during machining. By using a high-performance Field Programmable Gate Array (FPGA) system, process signals were continuously monitored, and characteristic values were extracted for analysis. Special attention was given to geometric features such as curves, which are particularly prone to deviations. This approach enables real-time process monitoring, offering potential for immediate corrective actions and contributing to improved machining accuracy and reliability. The findings provide valuable insights into the relationship between process parameters and contour quality, paving the way for advanced monitoring and control strategies in WEDM.