Published by : International Journal of Engineering Research & Technology (IJERT)

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Vol. 5 Issue 04, April-2016

Improved Electrical Discharge Machine (EDM)

Servomechanism Controller for Machining
Micro Pits
M. Olubiwe, L. O Uzoechi, V. C. Uchegbu,
Department of Electrical and Electronic Engineering,
Federal University of Technology,
Owerri, Nigeria.

Abstract - This research work is aimed at designing a better principle of EDM process is based on the thermoelectric
and more suitable servo control system to maintain an energy created between a workpiece and an electrode
accurate spark gap between the electrode and the workpiece. submerged in a dielectric fluid with the passage of electric
A poor performance of EDM servo controller results in longer current [2]. The workpiece and the electrode are separated
Ignition Delay Time, and inadequate speed of EDM machines
by a specific small gap called spark gap. In the EDM
in the micromachining process. Also, harmful arcing and
short circuit as a result of inaccurate position control of the process, there is no mechanical contact between the
machine electrode in relation to the work piece are electrodes and workpiece, and spark erosion is produced by
undesirable machining cases experienced in poorly controlled electrical discharge. This process has as its basic
EDM process. The objective of this paper is to design a good requirement the electrical conductivity of electrode and
servo system with a very good precision to obtain a better work-piece. A resistivity ranging from 100Ω/cm to
settling time. A PID controller is designed and fine-tuned with 300Ω/cm is also required for the electrodes. The dielectric
SIMULINK and MATLAB PID tuner to obtain suitable gains must have low viscosity, high dielectric strength, and quick
for faster and accurate response of the EDM process. Verified recovery after breakdown, effective quenching/cooling and
results obtained from the step response and Bode plot of the
flushing ability [4].
servo control system include: a settling time of 3.52 seconds,
the rise time of 1.05 seconds, the percentage overshoot of The electrical discharge in the EDM process causes strong
7.68%, the phase gain of 62 degrees at a frequency of heating of the workpiece material and electrode material
1.27rad/s, and a steady-state error less than 2%. The research tool, rapidly creating a small molten metal pool at the
work produced a better design and simulated results proved surface of the workpiece. The molten metal pool at the
the accuracy and precision of the servo controller. workpiece surface is flushed with dielectric in the form of
debris. The material removal rate is determined by the
Key Words: Micromachining, Servo-control, Electrical crater size and the frequency of crater generation (i.e.
discharge, Delay- Time, Ignition. discharge energy and the frequency of discharges). Also,
the cavity produced in the work piece is approximately the
I INTRODUCTION
replica of the tool [4]. A better explanation of EDM
The Electrical Discharge Machining (EDM) is a controlled
principle is provided by the EDM process. EDM is
process where pulsed of electrical discharge is used to
employed in industrial micromachining processes that
erode metal in a work-piece. In other words, Electrical
require high precision to produce best quality products
Discharge Machining is the machining method in which
involving micro pits with complex geometry. The
voltage is applied through a dielectric medium between the
electrode-to-workpiece spark gap is controlled by a servo
tool electrode and work-piece [1]. EDM can also be defined
control system. A poor performance of this EDM servo
as the process of machining electrically conductive
controller results in longer Ignition Delay Time, and
materials by using precisely controlled sparks that occur
inadequate speed of EDM machines in the micromachining
between an electrode and a work-piece in the presence of a
process. Also, harmful arcing and short circuit as a result of
dielectric fluid [2]. In typical industrial terms, EDM is a
inaccurate position control of the machine electrode in
controlled metal removal process that is used to remove
relation to the work-piece are undesirable machining cases
metal by means of electric spark erosion [3]. Electric
experienced in poorly controlled EDM process.
discharge machining provides an effective manufacturing
A good number of previous researches have been done in
technique that enables the production of parts made of
the field of Electrical Discharge Machining (EDM). [5]
special materials with complicated geometry which is
applied an intelligent approach for process modeling and
difficult to produce by conventional machining processes
optimization of electric discharge machining (EDM), Micro
[2].
Electrical Discharge Machine machining (Micro-EDM) as a
Modern day EDM (also known as spark machining or
powerful bulk micromachining technique that is applicable
Spark Erosion) process has been given a significant amount
to any type of electrical conductor was described in [6],
of research focus in manufacturing micro components and
including all kinds of metals and alloys as well as doped
highly advanced electrical discharge machines which are
semiconductors, in a research by [7] an experiment to
available for most machine applications. The working

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analyze the effect of machining parameters such as A DC servo motor is an actuator that converts electrical
discharge current (Ip), pulse on time (T on), voltage (v) over energy to mechanical rotation using the principles of
the responses of Material Removal Rate (MRR) and electromagnetism. DC servomotors are one of the main
Surface Roughness (SR) was performed. In the experiment, components of automatic systems. Any automatic system
various techniques were applied to improve the material should have an actuator module that makes the system to
removal rate (MRR), surface roughness (SR) and tool wear actually perform its function [8].
rate (TWR) with different electrode combination, [3] Figure 2 shows that a DC servomotor has two main
carried out a research on how servo control system can be components, the electrical and the mechanical components.
used to maintain the gap between Electrode and workpiece The electrical components consists of resistance,
in Electrical Discharge Machining (EDM), improving the inductance, input voltage and the back electromotive force.
performance of the machine. The mechanical component determines the mechanical
In this paper, the modelling and simulation of the Electrical rotational movement at the servomotor shaft. The
Discharge Machining (EDM) and a servo system controller mechanical component consist of the motor’s shaft, inertia
will be carried out in order to have a better performance of of the motor or load inertia and damping.
micro-machining positioning. Most DC Servomotors have good torque and speed
characteristics and are controlled by changing the voltage
II EDM DC SERVO MOTOR signal connected to the input. The parameters considered in
MATHEMATICAL MODEL figure 2 are denoted as follows:
A servomechanism (or simply Servo) is an automatic 𝑅𝑚 = resistance, 𝐿𝑚 = inductance, 𝑉𝑎 = applied or input
device that uses error-sensing feedback to correct the voltage, 𝑉𝑏 = the back electromotive force (emf), 𝐽𝑚 = load
performance of a control system. Figure 1 shows the block or shaft inertia, 𝑏𝑚 = damping, 𝜃𝑚 = angular position of the
diagram of an EDM servo control system. output shaft, 𝜔𝑚 = the angular speed of the shaft, 𝑇𝑚 = the
motor torque, 𝑖𝑚 = the current, 𝐾𝑚 = the torque constant.
Electronic From figure 2, the transfer function of the DC servomotor
Discharge can be derived using Kirchhoff’s voltage law and Laplace
SERVO Gap transforms as follows:
Input CONTROLLER
+ Applying Kirchhoff’s voltage law,
SYSTEM 𝑑𝑖
- 𝑉𝑎 = 𝑅𝑚 𝑖𝑚 + 𝐿𝑚 𝑚 + 𝑉𝑏 (1)
𝑑𝑡
The angular speed of the shaft, 𝜔𝑚 and the angular
position of the output shaft 𝜃𝑚 are connected by equation
SYSTEM (1)
Ignition Delay 𝑑𝜃
Time
𝜔𝑚 = 𝑚 = 𝜃̇ (2)
𝑑𝑡
The Back-electromotive force (emf), Vb can be expressed in
Nois terms of 𝜃𝑚 or 𝜔𝑚 as shown in equation (2)
e 𝑑𝜃
Figure 1: Block diagram of an EDM Servo Control System. 𝑉𝑏 (𝑠) = 𝐾𝑚 𝑚 = 𝐾𝑚 𝜔𝑚 (3)
𝑑𝑡
A servo is mostly employed in systems where the feedback Putting equation (3) into (1),
𝑑𝑖
or error-correction signals are applied to controlling 𝑉𝑎 = 𝑅𝑚 𝑖𝑚 + 𝐿𝑚 𝑚 + 𝐾𝑚 𝜔𝑚 (4)
𝑑𝑡
mechanical position or other parameters. Servomechanisms Taking the Laplace transform of equation (4),
are primarily driven by servo motors, especially DC servo 𝑉𝑎 (𝑠) − 𝑅𝑚 (𝑠)𝐼𝑚 (𝑠) − 𝐿𝑚 (𝑠)𝐼𝑚 (𝑠)𝑠 + 𝑉𝑏 (𝑠) (5)
motors. Figure 1 shows the block diagram of an EDM servo Expressing the current 𝐼𝑚 (𝑠) in terms of the other
control system.The circuit diagram of a servo motor is parameters in equation (5),
shown in figure 2. 𝑉 (𝑠)− 𝐾 (𝑠)𝜔𝑚 (𝑠)
𝐼𝑚 (𝑠) = 𝑎 (𝑠)𝑠𝑚 (6)
𝐿𝑚 + 𝑅𝑚(𝑠)
The mechanical component of the servomotor can be
represented by equation (7)
𝑑2𝜃 𝑑𝜃
𝐽𝑚 2𝑚 + 𝑏𝑚 𝑚 − 𝑇𝑚 = 0 (7)
𝑑𝑡 𝑑𝑡
But the motor torque 𝑇𝑚 can be written as in equation (8)
𝑇𝑚 = 𝐾𝑚 𝑖𝑚 (8)
Substituting equation (8) into (7) gives
𝑑 2 𝜃𝑚 𝑑𝜃𝑚
𝐽𝑚 + 𝑏𝑚 − 𝐾𝑚 𝑖𝑚 = 0 (9)
𝑑𝑡 2 𝑑𝑡
𝑑𝜃𝑚
in equation (9) can be replaced with equation (2) to
𝑑𝑡
obtain equation (10).
𝑑𝜔
𝐽𝑚 𝑚 + 𝐵𝑚 𝜔𝑚 − 𝐾𝑚 𝑖𝑚 = 0 (10)
Figure 2: A servomotor circuit Diagram. 𝑑𝑡
Taking the Laplace transform of equation (10),
𝐽𝑚 (𝑠)𝜔𝑚 (𝑠)𝑠 + 𝐵𝑚 (𝑠)𝜔𝑚 (𝑠) − 𝐾𝑚 (𝑠)𝐼𝑚 (𝑠) = 0 (11)

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Expressing the current in equation (11) 𝐼𝑚 (𝑠) in terms of stability. Figure 3 shows the control system model with
other parameters, general PID controller.
𝐽 (𝑠)𝜔𝑚 (𝑠)𝑠+ 𝐵𝑚 (𝑠)𝜔𝑚 (𝑠)
𝐼𝑚 (𝑠) = 𝑚 (12)
𝐾𝑚 (𝑠) P 𝑲𝒑 𝒆(𝒕)
Combining equations (6) and (12) gives the Transfer
Function of the servo motor, G(s) as shown in equations
𝒖(𝒕) 𝒚(𝒕)
(13). 𝒓(𝒕) 𝒆(𝒕) Plant
𝐽𝑚 (𝑠)𝜔𝑚 (𝑠)𝑠+ 𝐵𝑚 (𝑠)𝜔𝑚 (𝑠) 𝑉 (𝑠)− 𝐾 (𝑠)𝜔𝑚 (𝑠) I 𝒕
𝑲𝒊 ∫𝟎 𝒆(𝒕)𝒅𝒕
= 𝑎 (𝑠)𝑠𝑚 (13)
𝐾𝑚 (𝑠) 𝐿𝑚 + 𝑅𝑚 (𝑠)
𝜔𝑚 (𝐽𝑚 (𝑠)𝑠 + 𝐵𝑚 (𝑠))(𝐿𝑚 (𝑠)𝑠 + 𝑅𝑚 (𝑠)) = 𝒅𝒆(𝒕)
D 𝑲𝒅
𝐾𝑚 (𝑠)(𝑉𝑎 (𝑠) − 𝐾𝑚 (𝑠)𝜔𝑚 (𝑠)) (14) 𝒅𝒕

𝜔𝑚 (𝐽𝑚 (𝑠)𝑠 + 𝐵𝑚 (𝑠))(𝐿𝑚 (𝑠)𝑠 + 𝑅𝑚 (𝑠)) =

𝐾𝑚 (𝑠)𝑉𝑎 (𝑠) − 𝐾𝑚 (𝑠)2 𝜔𝑚 (𝑠) (15)
𝜔𝑚 (𝐽𝑚 (𝑠)𝑠 + 𝐵𝑚 (𝑠))(𝐿𝑚 (𝑠)𝑠 + 𝑅𝑚 (𝑠)) + 𝐾𝑚 (𝑠)2 = Figure 3: The Model of a PID Controller Configuration.
𝐾𝑚 (𝑠)𝑉𝑎 (𝑠) (16) From Figure 3, the mathematical expression for the three
𝜔𝑚 [(𝐽𝑚 (𝑠)𝑠 + 𝐵𝑚 (𝑠))(𝐿𝑚 (𝑠)𝑠 + 𝑅𝑚 (𝑠)) + 𝐾𝑚 (𝑠)2 ] = controller gains can be written as follows:
𝐾𝑚 (𝑠)𝑉𝑎 (𝑠) (17)  The proportional controller is an amplifier with
𝜔𝑚(𝑠) 𝐾𝑚(𝑠)
= [𝐽 2 (18) adjustable proportional gain, Kp. The action of this
𝑉𝑎 (𝑠) 𝑚 (𝑠)𝑠+ 𝐵𝑚 (𝑠)].[𝐿𝑚 (𝑠)𝑠+ 𝑅𝑚 (𝑠)]+ 𝐾𝑚 (𝑠)
𝜔𝑚(𝑠) controller depends on the error present . The equation is:
𝐺(𝑠) = (19)
𝑉𝑎 (𝑠) m(t) = Kpe(t) (23)
𝐾𝑚 (𝑠)
𝐺(𝑠) = [𝐽 2 (20) Where m(t) = controller output, Kp = Proportional
𝑚 (𝑠)𝑠+ 𝐵𝑚 (𝑠)].[𝐿𝑚 (𝑠)𝑠+ 𝑅𝑚 (𝑠)]+ 𝐾𝑚 (𝑠)
gain/sensitivity, and e(t) = actuating error signal
Equations (22) shows that the Transfer Function of the
 In the integral gain Ki or integral controller action (also
servo motor is the ratio of the angular speed of the shaft and
known as Reset Control), the output of the controller
the angular position. The standard parameter values of a
changes at a rate proportional to the actuating
typical Die-Sinking EDM servomechanism obtained
accumulation of past error signal e(t).
experimentally from a previous research (Ananya et al.,
integral gain, as shown in equation (24).
2011) are given as: 𝑅𝑚 = 4.0 Ω, 𝐿𝑚 = 2.75 x 10-6 H, 𝐽𝑚 = 𝑡
3.22 x 10-6 Kgm2, 𝐵𝑚 = 3.508 x 10-6 Nm/(rad/s), 𝐾𝑚 = m(t) = Ki∫0 𝑒(𝑡) + 𝑚(0) (24)
0.027 V/(rad/s) Where Ki = Integral gain, m(0) = Control output.
Substituting the above parameter values into eqation (20)  In the derivative control action or derivative gain Kd, the
gives the actual Transfer Function of the servo motor as output of the controller depends on the rate of change of
shown in equation (4). the actuating prediction of future error signal e(t). The
0.027 equation for D is written as
𝐺(𝑠) = [3.22 2 𝑑
x 10−6 𝑠+ 3.508 x 10−6].[2.75 x 10−6𝑠+ 4.0]+ 0.027
m(t) = Kd 𝑒(𝑡) (25)
(21) 𝑑𝑡
The three separate controller gains parameters involved in
𝜔𝑚(𝑠) 0.027 PID controller algorithm can be combined as in equation
𝐺(𝑠) = = (22)
𝑉𝑎 (𝑠) 𝑠 2 + 1.086𝑠 + 0.000779 (26).
𝑑𝑒(𝑡)
𝑢(𝑡) = 𝐾𝑝 𝑒(𝑡) + 𝐾𝑖 ∫ 𝑒(𝑡)𝑑𝑡 + 𝐾𝑑 (26)
III DESIGN SPECIFICATIONS 𝑑𝑡
a)Percentage overshoots less than 10% to a unit Ti = integral time and Td = derivative time.
step input. Applying the PID controller to any control system involves
b) Settling time less than 5 seconds to a unit step adjusting the values of gain Kp, Ki and Kd in order to get the
input. best response of the system. The selection of PID controller
c) Rise time of less than 2 seconds to a unit step gain values causes the variation of observed response with
input. respect to desired response.
d) Steady-state error less than 0.2%.
e) IV RESULT AND DISCUSSION
A EDM Controller (PID) Design The analysis and discussion of the results obtained from the
A Proportional Integral Derivative (PID) controller is a design of the Electrical Discharge Machining (EDM),
generic control loop feedback mechanism widely used in process mathematical model, servo control system
industrial control systems and is regarded as the standard modelling, and controller design and simulation is
control structures. A PID controller, sometimes called presented below. The results include the step responses of
three-term control, calculates an error value as the the EDM servomechanism, mathematical model transfer
difference between a measured process variable and a function as well as the improving effects of the controller
desired setpoint. The controller attempts to minimize the on the overall system.
error by adjusting the process through the use of a A PID Controller Tuning Using Mathlab/Simulink
manipulated variable. The PID controller has the optimum The actual PID controller gains from tuning Using
control dynamics including zero steady state error, fast MATLAB/SIMULINK are: 𝐾𝑝 = 59.3, 𝐾𝑖 = 0.655 and
response (short rise time), no oscillations and higher 𝐾𝑑 = 28.1. Putting these controller gains obtained from the

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tuning into a standard controller equation, this gives The control parameters obtained in figure 5 are: a settling
equation (27). time of 3.52 seconds, the rise time of 1.05 seconds, the
1
𝐺𝑐 (𝑠) = 59.3 + 0.655 + 28.1s (27) percentage overshoot of 7.68%, the phase gain of 62
𝑠
degrees at a frequency of 1.27rad/s, and a steady-state error
B Initial Step Response of EDM Servo Control
less than 2%. These servo control parameter values indicate
System Model
significant improvements in the performance of the system.
The initial performance of the EDM servo control system
Such improvements include a shorter and constant ignition
without a well tuned PID Controller was investigated by
delay time corresponding to the reduced rise time, and a
simulating equation 14 using MATLAB/SIMULINK. The
higher speed and accuracy of the EDM tool electrode
step response plot of the result are shown in figure 4. From
positioning to achieve the appropriate spark gap.
the plot, the open-loop response of the EDM servo control
system does not satisfy the design criteria at all. The
V CONCLUSION
settling time of 520 seconds, the rise time of 355 seconds,
the percentage overshoot of 0%, the phase gain of -120 In this research the servomechanism have been successfully
degrees at a frequency of 113.5rad/s, and a steady-state developed and simulated based on the initial, ignition and
error less than 5%. This describes a very poor stability of discharge phase of current and voltage gap. Also, the design
the system. It can be inferred from the plot that with the of a classical servo controller that optimizes the
open-loop response the system is partially unstable. It can performance of the EDM process is presented. The ultimate
also be interpreted that the response of the EDM) servo goal of the research is to improve the servomechanism of
control system without a well tuned PID is practically very an EDM process for a better efficiency of the EDM
slow and a longer ignition delay time. This can lead to micromachining process. The PID controller has been
uncontrolled performance of the EDM process as a result of successfully designed and fine-tuned with
non-linearities. MATLAB/SIMULINK and MATLAB PID tuner to obtain
suitable gains for faster and accurate response of the EDM
process. The PID controller gains obtained were integrated
with a servo control system to achieve a better result.
Moreover, the overall control system was improved to
establish a more intelligent and robust response of the EDM
process especially in our modern industries.

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