The research introduces new approaches to the control of electrical discharge machining (EDM) using advanced sensors and artificial intelligence. These methods enable real-time monitoring of discharges and precise process adjustment, ensuring higher quality and reliability of metallic components. The findings are directly applicable to the aerospace industry, contribute to the development of advanced medical devices, and improve the durability of industrial tooling, thereby supporting technological innovation and economic growth.
Electrical discharge machining is one of the key technologies for shaping complex metallic parts in aerospace, automotive, medical, and high-volume tooling applications. EDM makes it possible to manufacture intricate geometries in extremely hard materials. However, its performance is limited by the stochastic nature of discharges and the accumulation of removed material, which can lead to defects, tool wear, and increased production costs. Ensuring consistent product quality therefore remains a significant challenge.
Historically, process control has relied largely on operator experience and fixed machine settings. These conventional approaches often prove inadequate for mass production or for manufacturing parts requiring micrometer-level accuracy.
This study reviews state-of-the-art methods for in-situ process monitoring and control based on multi-modal sensing and artificial intelligence, enabling a more stable and predictable machining process.
“In-situ process monitoring and control in EDM: A review (Journal of Manufacturing Processes, IF ≈ 7), we analyzed cutting-edge strategies employing electrical, acoustic, and optical sensors to detect anomalies during discharge events. We highlighted the role of machine learning in identifying patterns within massive data streams and predicting faults before they occur. Furthermore, we examined feedback control systems capable of automatically adapting machining parameters to maintain consistent product quality. As a key future direction, we identified the development of digital twins, which will enable virtual testing and real-time optimization of EDM production processes, explains Assoc. Prof. Dr. Joško Valentinčič.