Experimental Investigation and Image-Assisted Electrode Tool Wear in the EDM Process

Authors

  • Ali Abbar Khleif College of Production Engineering and Metallurgy, University of Technology, Iraq
  • Osama A. Q. Ziada Department of Mechanical Engineering, Linnaeus University, Vaxjo, Sweden
  • Zaid M. A. A. Al-Zubaidi Alnukhba University College, Baghdad, Iraq
  • Ali M. Mustafa College of Production Engineering and Metallurgy, University of Technology, Iraq
  • Muhamed Abdul-Khadim Alaqeeli College of Production Engineering and Metallurgy, University of Technology, Iraq
  • Nadia Sami Hasan Ministry of Electricity, State Company of Electricity Production, Middle Region, Baghdad South Power Station, Iraq
Volume: 15 | Issue: 4 | Pages: 25514-25518 | August 2025 | https://doi.org/10.48084/etasr.11725

Received: 26 April 2025 | Revised: 1 June 2025 | Accepted: 16 June 2025 | Online: 2 August 2025


Corresponding author: Ali Abbar Khleif

Abstract

The present experimental investigation proposes an image-based assessment method for the automatic detection and measurement of convex end wear in cylindrical brass electrodes used during Electrical Discharge Machining (EDM) of AISI 314 steel plate workpieces. Minitab was utilized to determine the total number of experiments required for this study. The MATLAB Image Processing Toolbox was employed to classify and process images of cylindrical brass electrodes for extracting the data required in the data acquisition operation. The main objective of this study is to utilize a non-contact measurement system, along with a relatively low-cost instrumentation, to compute and evaluate the wear in cylindrical brass electrodes. The obtained wear values demonstrated that there is a slight skewed between the wear determined using a digitized caliper tool and the proposed image-assisted wear measurement, which validated the introduced method. The percentage of deviation between the proposed method and the method used by the digitized caliper tool-assisted wear measurement is 0.06.

Keywords:

electrical discharge machining, brass electrode, noncontact measuring system, image processing technique, material removal rate, electrode tool wear

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How to Cite

[1]
A. A. Khleif, O. A. Q. Ziada, Z. M. A. A. Al-Zubaidi, A. M. Mustafa, M. A.-K. Alaqeeli, and N. S. Hasan, “Experimental Investigation and Image-Assisted Electrode Tool Wear in the EDM Process”, Eng. Technol. Appl. Sci. Res., vol. 15, no. 4, pp. 25514–25518, Aug. 2025.

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