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<p>Electrical discharge machining (EDM) has been widely applied to superalloys and other difficult-to-cut materials, effectively reducing processing costs; however, the material removal rate (MRR) remains low. With the widespread application of difficult-to-cut materials in aerospace and other fields, there is an urgent need for machining technologies capable of addressing these challenges. This study proposes an upward sinking EDM (USEDM) technology and validates its superior efficiency and cost-effectiveness through systematic experimental investigations. To achieve optimal machining performance, a multi-factor optimization model was established combining a Kriging predictive surrogate model with a multi-objective particle swarm optimization (MOPSO) algorithm. The maximum MRR achieved using the globally optimized parameter combination obtained through the established multi-factor optimization model is 4013.07 mm<sup>3</sup>/min, which is several hundred times greater than that of conventional sinking EDM (CSEDM) and 13.31% higher than the unoptimized result. The maximum prediction errors of MRR and relative electrode wear rate (REWR) are 4.49% and 9.92%, respectively, demonstrating the high prediction accuracy of the proposed model. In addition, the optimized parameter combinations produced thinner recast layers and improved surface integrity. These results provide theoretical guidance for selecting appropriate machining parameters in USEDM under varying machining requirements for different difficult-to-cut materials, which will effectively promote the industrialization of USEDM.</p>

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Performance optimization of upward sinking electrical discharge machining based on multi-factor coupling analysis

  • 期刊论文

  • 发表日期：

    2025年10月16日

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  • Pengxin Zhang,
  • Yonghong Liu,
  • Haigang Zhang,
  • Xinlei Wu,
  • Haoxiang Lu,
  • Renpeng Bian,
  • Yujie Sun,
  • Chao Zheng,
  • Renjie Ji

摘要

Electrical discharge machining (EDM) has been widely applied to superalloys and other difficult-to-cut materials, effectively reducing processing costs; however, the material removal rate (MRR) remains low. With the widespread application of difficult-to-cut materials in aerospace and other fields, there is an urgent need for machining technologies capable of addressing these challenges. This study proposes an upward sinking EDM (USEDM) technology and validates its superior efficiency and cost-effectiveness through systematic experimental investigations. To achieve optimal machining performance, a multi-factor optimization model was established combining a Kriging predictive surrogate model with a multi-objective particle swarm optimization (MOPSO) algorithm. The maximum MRR achieved using the globally optimized parameter combination obtained through the established multi-factor optimization model is 4013.07 mm3/min, which is several hundred times greater than that of conventional sinking EDM (CSEDM) and 13.31% higher than the unoptimized result. The maximum prediction errors of MRR and relative electrode wear rate (REWR) are 4.49% and 9.92%, respectively, demonstrating the high prediction accuracy of the proposed model. In addition, the optimized parameter combinations produced thinner recast layers and improved surface integrity. These results provide theoretical guidance for selecting appropriate machining parameters in USEDM under varying machining requirements for different difficult-to-cut materials, which will effectively promote the industrialization of USEDM.