Ignition Delay Time Modeling in Wire-EDM

This study presents a comprehensive investigation and modeling of the ignition delay time ($t_d$) in wire-EDM (WEDM). The research focuses on the influence of gap distance, discharge energy, and piece height on the stochastic distributions of $t_d$, providing important insights into the complex properties of these distributions. Observations indicate that these parameters exert significant yet intricate influences on $t_d$, with a particular emphasis on the gap distance. A critical value was identified, around $8\mathsf{\mu }\mathrm{m}$ to $10\mathsf{\mu }\mathrm{m}$, that divides the stochastic behavior. To capture the binomial nature of $t_d$, a mixture probability model consisting of two Weibull distribution curves was developed and validated through extensive experimentation and a data analysis. The model demonstrated strong agreement with observed cumulative probability curves, indicating its accuracy and reliability in predicting $t_d$. Further, a sensitivity analysis revealed regions of fast change, emphasizing the challenges and importance of careful parameter selection in control of WEDM processes. The findings of this study contribute to a deeper understanding of WEDM processes and provide a modeling approach for predicting $t_d$. Future research directions include refining the model by incorporating additional input parameters, investigating the influence of other process variables on $t_d$.