https://sam.ensam.eu:443 The DSpace digital repository system captures, stores, indexes, preserves, and distributes digital research material. Sun, 12 Apr 2026 19:59:44 GMT 2026-04-12T19:59:44Z http://hdl.handle.net/10985/11344 Iterative surface warping to shape craters in micro‐EDM simulation SURLERAUX, Anthony; PERNOT, Jean-Philippe; ELKASEER, Ahmed; BIGOT, Samuel This paper introduces a new method for simulat- ing the micro-EDM process in order to predict both the tool’s wear and the workpiece’s roughness. The tool and workpiece are de ned by NURBS patches whose shapes result from an iterative crater-by-crater deformation technique driven by physical parameters. Through hundreds of thousands of local surface warping, the method is able to compute the global as well as the local shapes of the tool and workpiece. At each step, the warping vector and function are computed so as to be able to generate a spherical crater whose volume is also controlled. While acting very locally to simulate the real physical phenomenon, not only the method can evaluate the tool’s wear from the overall nal shape at a low resolu- tion level, but it can also estimate the workpiece’s roughness from the high resolution level. The simulation method is validated through a comparison with experimental data. Dif- ferent simulations are presented with an increase in compu- tation accuracy in order to study its in uence on the results and their deviation from expected values. Fri, 01 Jan 2016 00:00:00 GMT http://hdl.handle.net/10985/11344 2016-01-01T00:00:00Z SURLERAUX, Anthony PERNOT, Jean-Philippe ELKASEER, Ahmed BIGOT, Samuel This paper introduces a new method for simulat- ing the micro-EDM process in order to predict both the tool’s wear and the workpiece’s roughness. The tool and workpiece are de ned by NURBS patches whose shapes result from an iterative crater-by-crater deformation technique driven by physical parameters. Through hundreds of thousands of local surface warping, the method is able to compute the global as well as the local shapes of the tool and workpiece. At each step, the warping vector and function are computed so as to be able to generate a spherical crater whose volume is also controlled. While acting very locally to simulate the real physical phenomenon, not only the method can evaluate the tool’s wear from the overall nal shape at a low resolu- tion level, but it can also estimate the workpiece’s roughness from the high resolution level. The simulation method is validated through a comparison with experimental data. Dif- ferent simulations are presented with an increase in compu- tation accuracy in order to study its in uence on the results and their deviation from expected values. http://hdl.handle.net/10985/11337 A comparative study between NURBS surfaces and voxels to simulate the wear phenomenon in micro-EDM SURLERAUX, Anthony; BIGOT, Samuel; PERNOT, Jean-Philippe The prediction of the tool wear phenomenon in the micro electro discharge machining technology would be of a great use in the optimization of tool shapes. In order to do so, the ability to rapidly and precisely simulate the process is required. The choice of a geometrical model for the electrodes is of the utmost importance as it will condition the available methods for the simulation.Two geometrical models have been tested and implemented: NURBS and voxels embedded in an octree data structure. A limited experimental validation has been conducted and the results compared to the simulation through the use of the Hausdorff metric. Fri, 01 Jan 2016 00:00:00 GMT http://hdl.handle.net/10985/11337 2016-01-01T00:00:00Z SURLERAUX, Anthony BIGOT, Samuel PERNOT, Jean-Philippe The prediction of the tool wear phenomenon in the micro electro discharge machining technology would be of a great use in the optimization of tool shapes. In order to do so, the ability to rapidly and precisely simulate the process is required. The choice of a geometrical model for the electrodes is of the utmost importance as it will condition the available methods for the simulation.Two geometrical models have been tested and implemented: NURBS and voxels embedded in an octree data structure. A limited experimental validation has been conducted and the results compared to the simulation through the use of the Hausdorff metric. http://hdl.handle.net/10985/22735 Machine Learning-Based Reverse Modeling Approach for Rapid Tool Shape Optimization in Die-Sinking Micro Electro Discharge Machining SURLERAUX, Anthony; LEPERT, Romain; KERFRIDEN, Pierre; BIGOT, Samuel; PERNOT, Jean-Philippe This paper focuses on efficient computational optimization algorithms for the generation of micro electro discharge machining (µEDM) tool shapes. In a previous paper, the authors presented a reliable reverse modeling approach to perform such tasks based on a crater-by-crater simulation model and an outer optimization loop. Two-dimensional results were obtained but 3D tool shapes proved difficult to generate due to the high numerical cost of the simulation strategy. In this paper, a new reduced modeling optimization framework is proposed, whereby the computational optimizer is replaced by an inexpensive surrogate that is trained by examples. More precisely, an artificial neural network (ANN) is trained using a small number of full reverse simulations and subsequently used to directly generate optimal tool shapes, given the geometry of the desired workpiece cavity. In order to train the ANN efficiently, a method of data augmentation is developed, whereby multiple features from fully simulated EDM cavities are used as separate instances. The performances of two ANN are evaluated, one trained without modification of process parameters (gap size and crater shape) and the second trained with a range of process parameter instances. It is shown that in both cases, the ANN can produce unseen tool shape geometries with less than 6% deviation compared to the full computational optimization process and at virtually no cost. Our results demonstrate that optimized tool shapes can be generated almost instantaneously, opening the door to the rapid virtual design and manufacturability assessment of µEDM die-sinking operations. Mon, 01 Jun 2020 00:00:00 GMT http://hdl.handle.net/10985/22735 2020-06-01T00:00:00Z SURLERAUX, Anthony LEPERT, Romain KERFRIDEN, Pierre BIGOT, Samuel PERNOT, Jean-Philippe This paper focuses on efficient computational optimization algorithms for the generation of micro electro discharge machining (µEDM) tool shapes. In a previous paper, the authors presented a reliable reverse modeling approach to perform such tasks based on a crater-by-crater simulation model and an outer optimization loop. Two-dimensional results were obtained but 3D tool shapes proved difficult to generate due to the high numerical cost of the simulation strategy. In this paper, a new reduced modeling optimization framework is proposed, whereby the computational optimizer is replaced by an inexpensive surrogate that is trained by examples. More precisely, an artificial neural network (ANN) is trained using a small number of full reverse simulations and subsequently used to directly generate optimal tool shapes, given the geometry of the desired workpiece cavity. In order to train the ANN efficiently, a method of data augmentation is developed, whereby multiple features from fully simulated EDM cavities are used as separate instances. The performances of two ANN are evaluated, one trained without modification of process parameters (gap size and crater shape) and the second trained with a range of process parameter instances. It is shown that in both cases, the ANN can produce unseen tool shape geometries with less than 6% deviation compared to the full computational optimization process and at virtually no cost. Our results demonstrate that optimized tool shapes can be generated almost instantaneously, opening the door to the rapid virtual design and manufacturability assessment of µEDM die-sinking operations. http://hdl.handle.net/10985/11395 Computer-aided Micro-EDM die-sinking tool design optimisation SURLERAUX, Anthony; LEPERT, Romain; BIGOT, Samuel; PERNOT, Jean-Philippe This paper describes a new efficient method for computer aided optimisations of micro EDM die sinking tools, which can be used for design optimisation and performance verification in the digital domain. This would facilitate the integration and re-configurability of the micro EDM die sinking process in high value products manufacturing chains. An EDM simulation tool which makes use of voxels embedded in a voxel octree to represent the geometries is introduced and its application to a new Micro-EDM die-sinking tool shape optimisation is then described. Simulation results obtained with simple shapes are then discussed highlighting the capabilities of the new optimisation method and potential areas of improvement are proposed. Thu, 01 Jan 2015 00:00:00 GMT http://hdl.handle.net/10985/11395 2015-01-01T00:00:00Z SURLERAUX, Anthony LEPERT, Romain BIGOT, Samuel PERNOT, Jean-Philippe This paper describes a new efficient method for computer aided optimisations of micro EDM die sinking tools, which can be used for design optimisation and performance verification in the digital domain. This would facilitate the integration and re-configurability of the micro EDM die sinking process in high value products manufacturing chains. An EDM simulation tool which makes use of voxels embedded in a voxel octree to represent the geometries is introduced and its application to a new Micro-EDM die-sinking tool shape optimisation is then described. Simulation results obtained with simple shapes are then discussed highlighting the capabilities of the new optimisation method and potential areas of improvement are proposed. http://hdl.handle.net/10985/11389 Using voxels in the simulation of manufacturing processes SURLERAUX, Anthony; BIGOT, Samuel; D'URSO, Gianluca; MERLA, Cristina; PERNOT, Jean-Philippe The present paper introduces the use of voxels embedded in an octree structure in order to numerically simulate manufacturing processes. In particular, micro electrical discharge machining (μEDM) is used here as a case study. The involved elements (tool and workpiece) are modelized in a volumetric manner using voxels and the process is simulated on a step-by step basis. Comparisons using the Hausdorff metric with experimental results are included and discussed. Thu, 01 Jan 2015 00:00:00 GMT http://hdl.handle.net/10985/11389 2015-01-01T00:00:00Z SURLERAUX, Anthony BIGOT, Samuel D'URSO, Gianluca MERLA, Cristina PERNOT, Jean-Philippe The present paper introduces the use of voxels embedded in an octree structure in order to numerically simulate manufacturing processes. In particular, micro electrical discharge machining (μEDM) is used here as a case study. The involved elements (tool and workpiece) are modelized in a volumetric manner using voxels and the process is simulated on a step-by step basis. Comparisons using the Hausdorff metric with experimental results are included and discussed. http://hdl.handle.net/10985/11378 Estimating the exchanged energy distribution in micro-EDM BIGOT, Samuel; D'URSO, Gianluca; MERLA, Cristina; PEYROUTET, Jérémy; SURLERAUX, Anthony; PERNOT, Jean-Philippe This paper presents a new approach for the recording of the total quantity of energy exchanged during the micro Electro Discharge Machining (EDM) process. In particular, this approach allows for the estimation of the percentage of energy absorbed by the two electrodes (tool and workpiece) using a combination of theoretical models and experimental results, thanks to an advanced discharges measuring approach. The validity of several theoretical crater models was then assessed. Using this approach, the process was analysed for two electrode shapes and two sets of machining parameters. The preliminary results appears to fit those presented in the literature. Wed, 01 Jan 2014 00:00:00 GMT http://hdl.handle.net/10985/11378 2014-01-01T00:00:00Z BIGOT, Samuel D'URSO, Gianluca MERLA, Cristina PEYROUTET, Jérémy SURLERAUX, Anthony PERNOT, Jean-Philippe This paper presents a new approach for the recording of the total quantity of energy exchanged during the micro Electro Discharge Machining (EDM) process. In particular, this approach allows for the estimation of the percentage of energy absorbed by the two electrodes (tool and workpiece) using a combination of theoretical models and experimental results, thanks to an advanced discharges measuring approach. The validity of several theoretical crater models was then assessed. Using this approach, the process was analysed for two electrode shapes and two sets of machining parameters. The preliminary results appears to fit those presented in the literature. http://hdl.handle.net/10985/11343 Estimating the energy repartition in micro electrical discharge machining BIGOT, Samuel; D'URSO, Gianluca; MERLA, Cristina; SURLERAUX, Anthony; PERNOT, Jean-Philippe This paper presents a new approach for the recording of the total quantity of energy exchanged during the micro electrical discharge machining (EDM) process. In particular, this approach allows for the estimation of the percentage of energy absorbed by the two electrodes (tool and workpiece) using a combination of theoretical models and experimental results, thanks to an advanced discharges measuring approach. An experimental campaign was executed on a Sarix SX200 micro-EDM machine with a tungsten carbide tool electrode. In particular, the process was analyzed for two different electrode shapes, a triangular and a rectangular based parallelepipeds, and two sets of machining parameters. After the execution of the experimental campaign it estimate the total amount of energy that occurred during the entire die sinking process. The energy effectively lost into the tool, into the workpiece and into the dielectric was estimated from the measurement of the volume of material actually removed both from the tool and from the workpiece. The preliminary results appears to fit those presented in the literature and the validity of several theoretical crater models was then assessed. The validation of the presented acquisition method could enable the use of information related to energy repartition in the simulation of the micro-EDM process. Fri, 01 Jan 2016 00:00:00 GMT http://hdl.handle.net/10985/11343 2016-01-01T00:00:00Z BIGOT, Samuel D'URSO, Gianluca MERLA, Cristina SURLERAUX, Anthony PERNOT, Jean-Philippe This paper presents a new approach for the recording of the total quantity of energy exchanged during the micro electrical discharge machining (EDM) process. In particular, this approach allows for the estimation of the percentage of energy absorbed by the two electrodes (tool and workpiece) using a combination of theoretical models and experimental results, thanks to an advanced discharges measuring approach. An experimental campaign was executed on a Sarix SX200 micro-EDM machine with a tungsten carbide tool electrode. In particular, the process was analyzed for two different electrode shapes, a triangular and a rectangular based parallelepipeds, and two sets of machining parameters. After the execution of the experimental campaign it estimate the total amount of energy that occurred during the entire die sinking process. The energy effectively lost into the tool, into the workpiece and into the dielectric was estimated from the measurement of the volume of material actually removed both from the tool and from the workpiece. The preliminary results appears to fit those presented in the literature and the validity of several theoretical crater models was then assessed. The validation of the presented acquisition method could enable the use of information related to energy repartition in the simulation of the micro-EDM process. http://hdl.handle.net/10985/11334 Micro-EDM numerical simulation and experimental validation BIGOT, Samuel; SURLERAUX, Anthony; ELKASEER, Ahmed; PERNOT, Jean-Philippe This paper introduces a new method for simulating the micro-EDM process in order to predict tool wear. The tool and workpiece are defined by NURBS surfaces whose shapes result from an iterative crater-by-crater deformation technique driven by physical parameters. The simulation method is validated through a comparison with experimental data. Different simulations are presented with an increase in computation accuracy in order to study its influence on the results and their deviation from expected values. Tue, 01 Jan 2013 00:00:00 GMT http://hdl.handle.net/10985/11334 2013-01-01T00:00:00Z BIGOT, Samuel SURLERAUX, Anthony ELKASEER, Ahmed PERNOT, Jean-Philippe This paper introduces a new method for simulating the micro-EDM process in order to predict tool wear. The tool and workpiece are defined by NURBS surfaces whose shapes result from an iterative crater-by-crater deformation technique driven by physical parameters. The simulation method is validated through a comparison with experimental data. Different simulations are presented with an increase in computation accuracy in order to study its influence on the results and their deviation from expected values.