The minimization of the workpiece surface damage due to randomly occurring arcing and the improvement in the process performance are the main objectives of the gap monitoring and control system incorporated with the state-of-the-art commercially available EDM units. This paper evaluates the effect of a recently developed control system based on monitoring of Radio Frequency signal on the surface integrity of components machined by EDM. The experimental results of machining AISI 4130 steel and Titanium Carbide Adamas Titan 80 under the existing machine control, orbital motion and/or R.F. control indicate a substantial improvement in surface integrity with R.F. control. The effect of R.F. parameters on process performance and surface damage is further investigated by modelig and analyzing the surface profile characteristics using Data Dependent Systems methodology.
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