Study of New Era in AI driven Modeling and Comparative Analysis of VEAM and Continuous Arc EDM for Advanced Machining Applications in Machine Design

Study of New Era in AI driven Modeling and Comparative Analysis of VEAM and Continuous Arc EDM for Advanced Machining Applications in Machine Design

Samudrala Asha Kumar1, Kakumanu Rajesh2

1PG Scholar, Dept. of Mechanical Engineering, Chebrolu Engineering College, Chebrolu, Guntur, A.P, India.

2Associate Professor, Dept. of Mechanical Engineering, Chebrolu Engineering College, Chebrolu, Guntur, A.P, India.

Abstract - This research study presents a comprehensive investigation into two innovative electrical discharge-based machining processes: Vibration-Assisted Electrical Arc Machining (VEAM) and High-Speed EDM Milling with Moving Electric Arcs, both designed to machine electrically conductive and difficult-to-cut materials such as Al/B4C metal matrix composite (MMC) and Titanium alloy. VEAM is a modified form of Electrical Arc Machining (EAM) in which the tool is mechanically vibrated to improve spark stability, debris removal, and energy efficiency. A custom-built VEAM machine was developed, and key process parameters—such as peak current, pulse-on and off times, dielectric flushing velocity, and vibration frequency—were experimentally analyzed using the Box-Behnken Design of Experiments. The material removal rate (MRR) and tool wear rate (TWR) were modeled using second-order regression models and artificial neural networks (ANNs). The ANN models demonstrated superior prediction accuracy (R > 0.98) compared to regression models (R = 0.9–0.95). For process optimization, a hybrid approach combining ANN with modern metaheuristic algorithms such as Sine Cosine Algorithm (SCA) and Rao-3 algorithm was applied. This led to significant performance improvements, including a 40% increase in MRR and a 12% reduction in TWR for MMCs, and notable efficiency gains for Titanium alloys. In parallel, the study explores a novel high-speed EDM milling technique utilizing moving electric arcs powered by direct current (DC). Unlike conventional EDM, which operates with pulsed sparks and discharge intervals, this approach maintains a continuous arc movement between the electrode and the work piece. A specially designed high-speed EDM setup was developed to capture the motion dynamics and resistance behavior of the arc. Using speed videography, the plasma channel of the electric arc was visualized, revealing independent arc movement that enhances machining stability and material removal. Experiments on Titanium alloy validated the theoretical findings, showing that MRR is significantly higher than in traditional EDM, while tool electrode wear is remarkably low due to the formation of a protective layer on the tool surface during machining. Together, these two advanced approaches represent complementary advancements in the field of non-traditional machining. VEAM leverages intelligent modeling and optimization to fine-tune process efficiency, while the high-speed EDM milling process revolutionizes continuous arc-based material removal. This combined insight opens new pathways for high precision and high-efficiency machining of advanced materials in aerospace, biomedical, and automotive sectors.

Key Words:  Electrical Arc Machining, Vibration-Assisted Electrical Arc Machining, Mechanical Properties, Thermal Properties, Blasting erosion arc machining, Electro chemical arc machining.