Evaluation of die-sinking Electric Discharge Machine with Smart Machine Controller

A programmable logical control based Smart Machine Controller (SMC) has been developed to control the EDM process. SMC extracts the EDM process variables for rough, semi-finish and finish machining operations from the developed database. The experimental database was created by conducting pilot experimentations after conducting the validation experiments, the SMC was tested on six different dies and mold steel materials with original machine controller and the results show that the MRR and surface finish improved significantly when used with SMC machining parameters. The developed SMC is very effective and highly interactive when compared to the original die-sinking EDM machine controller.