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Simulation for Electrode Wear Predication in Die-Sinking EDM Based on Geometry Model

To solve the electrode wear compensation in die-sinking Electric Discharge Machining (EDM), a new electrode wear simulation method based on geometry model is put forward. The 3D unit grid technology was used to set up the geometric model for pulse discharge region. The minimum gap searching technology was taken to recognize the exact pulse discharge position and the cone was used to simulate discharge unit. Combining with the analysis of work-piece desired shape and electrode wear mechanism, the compensation and appropriate final shape of electrode was achieved. The result shows that it can predict the electrode wear effectively and its feasibility is discussed in die-sinking DEM.