Accurate prediction of Electro-Discharge Machining (EDM) results is crucial for industrial applications, aiming to achieve high-performance and cost-efficient machining. However, both the current physical model and the standard Artificial Neural Network (ANN) model exhibit inherent limitations, failing to fully meet the accurate requirements for predicting EDM machining results. In addition, Micro-EDM Drilling can lead to the distortion of the macroscopic shape of machining pits under different input conditions, rendering the use of only the volume of machining pits as the evaluation index insufficient to express the complete morphological information. In this study, we propose a novel hybrid prediction model that combines the strengths of both physical and data-driven models to simultaneously predict Material Removal Rate (MRR) and shape parameters. Our experiment demonstrates that the hybrid model achieves a maximum prediction error of 4.92% for MRR and 5.28% for shape parameters, showcasing excellent prediction accuracy and stability compared to the physical model and the standard ANN model.
Keywords: BP-ANN; EDM; GA; MRR; modeling; shape.