Assessing the performance of state-of-the-art machine learning algorithms for predicting electro-erosion wear in cryogenic treated electrodes of mold steels

In manufacturing, predicting and reducing electro-erosion wear during the electric discharge machining (EDM) process is critical to minimize delays, financial losses and product defects. Achieving this requires developing and evaluating accurate machine learning models. In our study, we focus on cryogenically treated mold steel electrodes to investigate the potential of different machine learning algorithms to predict EDM wear. We considered five machine learning algorithms—artificial neural networks, ensemble learning, boosting algorithms, tree-based algorithms, and k-nearest neighbors—to evaluate their ability to predict wear patterns accurately. Each algorithm was trained and tested using actual experimental data from EDM processes. Our results show that the machine learning models demonstrated exceptional accuracy, accurately predicting EDM wear in training and testing datasets with almost 99% accuracy. In addition, we identified the most influential characteristics that affect wear patterns, including operating current, cryogenic process parameters, and electrode composition. Based on these findings, manufacturers can gain valuable insight into the factors that cause EDM wear and optimize their EDM processes accordingly to improve productivity, reduce wear-related costs, and increase production quality across multiple manufacturing industries. Furthermore, this research provides insights into the possibilities of implementing these models in real manufacturing contexts and motivates future research on this topic. Ultimately, integrating advanced computing techniques and prudent decision-making strategies will shape the future of manufacturing operations management and promote sustainable and profitable business growth.