In-Situ Measurement of Electrode Wear During EDM Drilling using Vision System

  • Z. Hamedon
  • I. Razemi
  • A. Azhari
  • A.R. Yusoff


Machine vision system is an image-based technology used to perform automatic inspection and analysis such as process control and robot guidance. The aim for this project is to develop a fully automated electrode wear detection system in EDM by using machine vision system and apply this system in detecting electrode wear in EDM. This project was conducted using DSLR camera as monitoring device. The electrode undergo hole making process with a depth of 10 mm, 20 mm, 30 mm, 40 mm, and 50 mm to observe the electrode condition. The image of the electrode will be remotely captured from the laptop and then will undergo image processing process using Matlab software to calculate and determine the electrode wear. The output of this project will show the images of the electrode wear and its wear value. Findings from the project showed that this system is suitable and applicable in EDM super drill machine to monitor the tool condition.


Download data is not yet available.


K. Ho and S. Newman, “State of the art electrical discharge machining (EDM),” International Journal of Machine Tools and Manufacture, vol. 43, no. 13, pp. 1287-1300, 2003.

J. Brown, Advanced Machining Technology. UK: McGraw-Hill, 1998.

C. S. Lee, E. Y. Heo, J. M. Kim, I. H. Choi and D. W. Kim, “Electrode wear estimation model for EDM drilling,” Robotics & Computer-Integrated Manufacturing, vol. 36, pp. 70-75, 2015.

E. Ferraris, V. Castiglioni, F. Ceyssens, M. Annoni, B. Lauwers and D. Reynaert, “EDM drilling of ultra-high aspect ratio micro holes with insulated tool,” CIRP Annals - Manufacturing Technology, vol. 62, no. 1, pp. 191-194, 2013.

A. Azhari, Z. Hamedon and M. A. Gebremariam, “A study on wire breakage in electrical discharge machining of polyurethane foam,” Materials Today: Proceedings, vol. 4, no. 4, pp. 5222–5227, 2017.

Z. Hamedon, T. T. Mon, T. Sharif, A. R. M. Masri and E. Sue-Rynley, ”Performance of nitrogen gas as a coolant in machining of titanium,” Advanced Materials Research, vol. 264 - 265, pp. 962-966, 2011.

M. -T. Yan, K.-Y. Huang and C.-Y. Lo, “A study on electrode wear sensing and compensation in Micro-EDM using machine vision system,” The International Journal of Advanced Manufacturing Technology, vol. 42, no. 11-12, pp. 1065-1073, 2009 .

S. Maidin, H. H. El-Grour and C. Seeying, “Comparative study of material removal rate and tool wear rate of copper and aluminium on die sinking EDM,” Jurnal Teknologi (Sciences & Engineering) vol. 77, no. 21, pp. 51-58, 2015.

Z. Hamedon, K. Mori and Y. Abe, “In-situ measurement of three-dimensional deformation behavior of sheet and tools during stamping using borescope,” Journal of Materials Processing Technology, vol. 214, no. 4, pp. 945-950, 2014.

Z. Hamedon, K. Mori and Y. Abe, “Hemming for joining high strength steel sheets,” Procedia Engineering, vol. 81, pp. 2074-2079, 2014.

T. Maeno, K. Mori and Z. Hamedon, “Hot bending of titanium alloy sheet using resistance heating,” Steel Research International SPECIAL ISSUE, pp. 287-290, 2012.

Z. Zulkoffli and A.B. Elmi, “Template based defect detection of flexible printed circuit,” Jurnal Teknologi (Sciences & Engineering), vol. 78, no. 1, pp. 153–158, 2016.

S. A. Idris, F. A. Jafar and N. Abdullah, “Study on corrosion features analysis for visual inspection & monitoring system: An NDT Technique,” Jurnal Teknologi (Sciences & Engineering), vol. 77, no. 21, pp. 59–65, 2015.

Y. Saotome, K. Yasuda and H. Kaga, 2001, “Microdeep drawability of very thin sheet steels,” Journal of Materials Processing Technology, vol. 113, no. 1–3, pp. 641-647, 2015.

R. Izamshah, M. Akmal, M. S. Kasim, S. A. Sundi and M. Hadzley, “A statistical comparison of screening wire-edm parameters for machining titanium alloy,” Journal of Advanced Manufacturing Technology, vol. 10, no. 2, pp. 45-55, 2016.

M. Najiha, M. Rahman, M. Kamal, A. Yusoff and K. Kadirgama, “Minimum quantity lubricant flow analysis in end milling processes: A CFD approach,” Journal of Mechanical Engineering and Sciences, vol. 3, pp. 340-345, 2012.

M. A. Rahman, M. M. Rahman and K. Kadirgama, “Electrode wear rate of graphite electrodes during electrical discharge machining processes on titanium Alloy TI-5AL-2.5SN,” International Journal of Automotive and Mechanical Engineering, vol. 9, pp. 1782-1792, 2014.

How to Cite
Hamedon, Z., Razemi, I., Azhari, A., & Yusoff, A. (1). In-Situ Measurement of Electrode Wear During EDM Drilling using Vision System. Journal of Advanced Manufacturing Technology (JAMT), 12(1(2), 513-524. Retrieved from