Inverse Simulation of Die-Sinking EDM

Abstract

This research aims to develop a simulation method for die-sinking EDM to solve the inverse problem of obtaining the appropriate tool electrode shape for achieving the desired final workpiece shape. In the reverse simulation method developed, the same algorithm as that used in forward simulation is adopted. The workpiece is however fed towards the tool electrode in the direction opposite to forward simulation, and the values for the depth of the layers removed from the tool electrode and workpiece surface per pulse discharge are the reverse of forward simulation. The algorithm is a simple repetition of the procedure comprised of: 1) determining the next discharge location, 2) removing the tool and workpiece electrodes, 3) distributing the debris particles, and 4) feeding the tool electrode.