Fuzzy approach to select machining parameters in electrical discharge machining (EDM) and ultrasonic-assisted EDM processes

Condition monitoring of the machining process is very important in today's precision manufacturing, especially in the electrical discharge machining (EDM). This paper introduces a fuzzy-based algorithm for prediction of material removal rate (MRR), tool wear ratio (TWR), and surface roughness (R-z, R-k) in the EDM and ultrasonic-assisted EDM (US/EDM) processes. In this system, discharge current, pulse duration, and ultrasonic vibration of tool are the input variables and outputs are MRR, TWR, R-z, and R-k. The proposed fuzzy model in this study provides a more precise and easy selection of EDM and US/EDM input parameters, respectively for the required MRR, TWR, R-z, and R-k, which leads to better machining conditions and decreases the machining costs. The fuzzy modeling of EDM and US/EDM were able to predict the experimental results with accuracies more than 90%. (C) 2012 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.