Feasibility of wear compensation in micro EDM milling based on discharge counting and discharge population characterization

This paper investigates the applicability of real time wear compensation in micro EDM milling based on discharge counting and discharge population characterization. Experiments were performed involving discharge counting and tool electrode wear measurement in a wide range of process parameters settings involving different current pulse shapes. A strong correlation is found between average discharge energy of the populations and wear and material removal per discharge. A validation was carried out showing the feasibility of the proposed approach.