Now-a-days, many sophisticated systems are available to monitor the process in real time that drastically reduce the cost and lead time to manufacture a part because it takes away the offline sampling. For Electrical Discharge Machining (EDM), current signal monitors are very useful to predict the material removal rate and determine the arcing that can damage the surface. This paper discusses the design and development of an online monitoring for micro-EDM using correlation developed via experimentation. Surface roughness is predicted based on online monitoring.

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