An on-line adaptive control of the Electrical Discharge Machining (EDM) process needs proper quantitative relationships between output parameters and input variables of the process. An attempt is presented to develop mathematically simple expressions for the depth of cracks, the depth of damaged layer, and the depth of martensitic layer in terms of pulse duration and current. The transient temperature distribution developed by Data Dependent Systems analysis of the EDM process is used in obtaining thermal stress expressions. Regression equations suitable for the on-line adaptive control of the EDM process are developed. The theoretical estimates are compared with the experimental measurements.
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