A comparative investigation on temperature distribution in electric discharge machining process through analytical, numerical and experimental methods

Shahri, Hamid Reza Fazli; Mahdavinejad, Ramezanali; Ashjaee, Mehdi; Abdullah, Amir

doi:10.1016/j.ijmachtools.2016.12.005

Cited by 61 publications

(20 citation statements)

References 84 publications

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“…It is due to the temperature distribution during spark on time and a considerable rise of temperature adequate to melt the tool. Similar kind of results is also reported by previous researchers (Fazli Shahri et al , 2017; Zhang et al , 2013; Kansal et al , 2008).…”

Section: Resultssupporting

confidence: 92%

“…Chakraborty et al (2015) have performed a literature review of dielectric fluids and effects in EDM characteristics and show that gas as a dielectric medium has an advantage of lower tool wear ratio independent of pulse on time. Fazli Shahri et al (2017) have developed a thermal model and studied the different temperature distribution methods in the EDM process through an analytical, numerical and experimental approach. The results obtained by these methods proved that FEM and FDM, are powerful tools to be used for estimating the temperature distribution considering variable thermo-physical properties.…”

Section: Literature Reviewmentioning

confidence: 99%

“…To study the intricate nature of the EDM tool material evacuation process, few assumptions are made in the thermal model. Owing to make an approach simpler and convenient, following are the assumptions are made in the existing study (Fazli Shahri et al , 2017; Sarikavak and Cogun, 2012; Zhang et al , 2013; Kansal et al , 2008) Single spark model is considered for fixed cycle time. The cathode material is homogeneous and isotropic. The conduction is the mode of heat transfer for the tool (cathode). Plasma forms a cylindrical heat energy source on the cathode. The plasma passage has a uniform cylinder shape. The axisymmetric model is used. Heat transfer due to radiation is neglected. The Gaussian heat distribution principle is used. …”

Section: Thermal Modelmentioning

confidence: 99%

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Simulation and experimental investigation of tool wear rate in dry and near-dry EDM process

Ganachari

Chate²,

Waghmode³

et al. 2021

WJE

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Purpose Many engineering applications in this era require new age materials; however, some classic alloys like spring steel are still used in critical applications such as aerospace, defense and automobile. To machine spring steel material, there exist various difficulties such as rapid tool wear rate, the rough surface formation of a workpiece and higher power consumption. The purpose of this paper is to address these issues, various approaches in addition to electrical discharge machines (EDM) are used such as dry EDM (DEDM) and near dry EDM (NDEDM). Design/methodology/approach This study focuses on these two approaches and their comparative analysis with respect to tool wear during machining of spring steel material. For this study, current, gap voltage, cycle time and dielectric medium pressure are considered input variables. This study shows that the near dry EDM approach yields better results. Hence, the thermo-electrical model for this approach is developed using ANSYS workbench, which is further validated by comparing with experimental results. This thermo-electrical model covers spark radius variation and formation of temperature profile due to electric discharge. Transient thermal analysis is used to simulate the electric discharge machining. Findings It is observed from this study that discharge environment parameters such as debris concentration and fluid viscosity largely influences the dielectric fluid pressure value. Experimental results revealed that NDEDM yields better results in comparison with DEDM as it shows a 25% lesser tool wear rate in NDEDM. Originality/value The range of predicted results and the experimental results are in close agreement, authenticating the model.

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Section: Resultssupporting

confidence: 92%

Section: Literature Reviewmentioning

confidence: 99%

Section: Thermal Modelmentioning

confidence: 99%

See 1 more Smart Citation

Simulation and experimental investigation of tool wear rate in dry and near-dry EDM process

Ganachari

Chate²,

Waghmode³

et al. 2021

WJE

View full text Add to dashboard Cite

show abstract

“…Depending on the frequency, this process can happen several to hundreds of times in a second, thus creating multiple overlapping craters. Although the EDM process is a combination of different phenomena, such as dielectric break down, plasma formation, heat conduction, fluid dynamics, electrical phenomenon, chemical phenomenon, etc., thermal effects with a small error can be considered as the dominating phenomenon in the EDM process [1][2][3][4][5].…”

Section: Introductionmentioning

confidence: 99%

Modeling of Material Removal Rate and Surface Roughness Generated during Electro-Discharge Machining

et al. 2019

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This study reports on the numerical model development for the prediction of the material removal rate and surface roughness generated during electrical discharge machining (EDM). A simplified 2D numerical heat conduction equation along with additional assumptions, such as heat effect from previously generated crater on a subsequent crater and instantaneous evaporation of the workpiece, are considered. For the material removal rate, an axisymmetric rectangular domain was utilized, while for the surface roughness, a rectangular domain where every discharge resides at the end of previous crater was considered. Simulated results obtained by solving the heat equation based on a finite element scheme suggested that results are more realistic by considering instantaneous evaporation of the material from the workpiece and the effect of residual heat generated from each spark. Good agreement between our model and previously published data validated the newly proposed models and demonstrate that instantaneous evaporation, as well as residual heat, provide more realistic predictions of the EDM process. Machines 2019, 7, 47 2 of 17 model where the problem of heat conduction for both infinite and semi-infinite bodies with a constant heat source was solved. DiBitonto et al. [7] developed a point heat source cathode erosion model. Since spherical symmetry was considered in their model, the heat transfer equation in spherical coordinates was implemented. In their model, the constant cathode energy fraction of 0.183 was assumed. In their subsequent study [8], they developed an anode erosion model, by assuming a disk heat source. Beck et al.[9] developed a model to find the temperature distribution of a semi-infinite cylinder with a constant heat source and an insulated boundary. Since this model was not developed particularly for the EDM process, the heat fraction to the workpiece is not considered.Process performances of EDM have been investigated by many researchers. D'Urso et al.[10] defined a process index based on process parameters and material properties to analyze the process and geometric indexes of micro-EDM process. D'Urso and Ravasio [11], based on a material-technology index (MTI), studied the process performance of micro-EDM. Tsai and Masuzawa [12] analyzed the electrode wear of different electrode materials in a micro-EDM process. Based on experimental results, a new wear resistance index based on modified boiling and melting points for the evaluation of erosion performance was proposed. Marafona and Araujo [13] proposed an additive model to investigate the influence of hardness on the material removal rate and surface roughness. Alshemary et al. [14] studied effects of different process parameters on fabricating cylindrical holes by wire-EDM. Mandal et al. [15] investigated the surface integrity of wire-EDM. They reported that both grinding and etching-grinding techniques removed the recast layer, and hence improved the surface integrity. Prakash et al. [16] proposed altering the EDM process for coating TiO 2 -T...

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“…Assuming that the total energy of spark consumed in melting and vaporization of workpiece surface resulted into the formation of hemispherical shape crater, the increase in the peak current and pulse duration causes plasma radius growth. The plasma radius r p is given by 4,10,30–32 where K'1, a and b are the constants determined experimentally. Das et al.…”

Section: Modeling Of Mrrmentioning

confidence: 99%

Modelling of material removal rate in the magnetic field and air-assisted electrical discharge machining

Beravala

Pandey

2019

Proceedings of the Institution of Mechanical Engineers, Part C:

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In the present research work, an attempt has been made to develop the mathematical model to predict the material removal rate in the electrical discharge machining process when the assistance of air and magnetic field is provided together. The proposed model incorporates the physical phenomenon occurred during electrical discharge machining such as the plasma column expansion and reduction in the mean free path of electron in the plasma column due to magnetic field. In addition, the model incorporates the effect of air on the material removal rate. The developed model correlates the material removal rate with the process parameters such as the peak current, pulse duration, duty cycle, air pressure and magnetic flux density. The experimental data were used to evaluate the constants for district processing conditions. The relation between air pressure and breakdown voltage in the liquid-air mixed dielectric has been established experimentally. The obtained expression of material removal rate has been validated for the experimental conditions other than that used for obtaining constants. The results show less than 10% error in the prediction by the model over the respective experimental values.

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A comparative investigation on temperature distribution in electric discharge machining process through analytical, numerical and experimental methods

Cited by 61 publications

References 84 publications

Simulation and experimental investigation of tool wear rate in dry and near-dry EDM process

Simulation and experimental investigation of tool wear rate in dry and near-dry EDM process

Modeling of Material Removal Rate and Surface Roughness Generated during Electro-Discharge Machining

Modelling of material removal rate in the magnetic field and air-assisted electrical discharge machining

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