Real-time monitoring and diagnosing in wire-electro discharge machining

This paper presents the design and development of a real-time monitoring and diagnostic system for diagnosing the degraded behaviour in wire-electro discharge machining. The detection in advance of the degraded behaviour is crucial since this can lead to the breakage of the cutting tool (the wire), reducing the process productivity and the required accuracy (Ho et al., Tools Manuf 44:1247-1259, 2004). This work presents the design and development of a real-time monitoring system that alerts the degraded behaviour. It can detect different types of degraded behaviours that have been previously identified during the analysis phase. Unlike other works found in the literature review, which are focussed on proprietary hardware, the present paper proposes a flexible real-time platform based on a commercial data acquisition board that can be easily configured for different purposes. It has been applied to develop a real-time monitoring and diagnostic system that uses virtual sensors to diagnose the degradation of the process. The results of this work show a satisfactory performance of the presented approach.