Energy consumption modeling for EDM based on material removal rate

In recent years, the energy problem has caused widespread concern in the manufacturing industry. The energy consumption in traditional turning and milling processes has been widely studied. However, there are few studies on the energy consumption of the EDM (Electric Discharge Machining) process, which is also widely used. This article proposed a modeling method for the energy consumption model of EDM based on the discharge between electrodes. The proposed model is composed of processing energy consumption caused by electrode-to-electrode discharge and no-load energy consumption of the machine tool. Based on the discharge principle of EDM and the relationship between EDM machining parameters and MRR (Material Removal Rate), an energy consumption model for EDM machining is established. In this article, validation experiments are designed for important machining parameters, and the prediction accuracy of the theoretical model established in this article is higher than 96%. The energy efficiency in electric machining is also analyzed, and the influence relationship between energy consumption and machining parameters is revealed, which can effectively reduce the energy consumption of electric spark punching.