The integration of the state‐of‐the‐art monitoring and adaptive control technologies can substantially improve the performance of EDM process. This paper reports the development of an adaptive speed control system for micro EDM which demands a higher level of accuracy. Monitoring of the machining state is conducted during the machining process so that the conditions are analysed continuously. Various schemes for the machining state are used for decision making. For instance, upon recognition of abnormal discharges, the developed adaptive speed control system would adjust the electrode feeding speed in an attempt to correct the machining state. Experimental verification shows that the proposed system can improve the machining time by more than 50%. In addition, a more accurate machined feature can be produced as compared to traditional EDM servo control systems.

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