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A deterministic reverse engineering framework for multi-stage EDM: optimizing stage selection and parameters for efficiency and surface integrity
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DOI：10.1088/2631-8695/ae4679.png)
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Abstract
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Electrical discharge machining (EDM) is crucial for materials at high-hardness but is often characterized by complex, non-linear processes and conflicting outputs such as material removal rate (MRR) and surface roughness (Ra). Traditional industrial practice relies on sub-optimal, fixed two-stage sequences (roughing and finishing), necessitating a robust solution to the inverse problem: systematically determining the optimal process inputs required to satisfy multiple predefined output criteria. This study presents a deterministic reverse engineering framework for multi-stage EDM, utilizing backward constraint propagation to determine the optimal number of stages and precise parameters. The process begins with the desired final Ra and works backward, embedding crucial physical constraints: setting subsequent cutting depth to 2-3 times the average white layer thickness (AWLT) of the prior stage to ensure complete removal of sub-surface damage, and incorporating stage-specific electrode wear rate (EWR) compensation. The framework consistently identified the five-stage configuration as optimal across all operational tests. This optimized sequence yielded a massive 57.00% reduction in total machining time compared to the conventional two-stage operational baseline. The transition from two to three stages-the primary innovation-accounted for a 52.55% improvement over current industry practice alone. Comparative benchmarking confirmed this superiority, achieving machining times 16.9% to 32.4% faster than fixed three-stage approaches reported in the literature. Furthermore, comprehensive sensitivity analyses demonstrated the framework's deterministic stability and universality, with the five-stage configuration remaining optimal across diverse workpiece geometries (cylinders, L-shapes) and performance variations below 0.1%. Sustainability analysis revealed significant benefits: the optimal approach achieved a 98.4% reduction in energy consumption (from 251.16 kWh to 3.96 kWh per part).This methodology provides a robust, systematic solution for high-efficiency EDM planning, drastically enhancing efficiency, preserving surface integrity.
Keywords:
electrical discharge machining (EDM)
reverse engineering
multi-stage optimization
surface roughness (Ra)
average white layer thickness (AWLT)
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