A finite element based model for electrochemical discharge machining in discharge regime

Wei, Chenjun; Xu, Kun; Ni, Jun; Brzezinski, Adam J.; Hu, De Jin

doi:10.1007/s00170-010-3000-0

Cited by 62 publications

(26 citation statements)

References 19 publications

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“…The percentage of energy transferred to the workpiece is given by a term called coefficient of energy transfer (C T ) whose value is around 0.2 [6]in the case of ECDM. Hence the total energy transferred to the work can be expressed as (3).…”

Section: E = I (T)v (T)dtmentioning

confidence: 99%

A mathematical model for surface roughness of fluidic channels produced by grinding aided electrochemical discharge machining (G-ECDM)

Ladeesh

Manu

2017

MATEC Web Conf.

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Abstract. Grinding aided electrochemical discharge machining is a hybrid technique, which combines the grinding action of an abrasive tool and thermal effects of electrochemical discharges to remove material from the workpiece for producing complex contours. The present study focuses on developing fluidic channels on borosilicate glass using G-ECDM and attempts to develop a mathematical model for surface roughness of the machined channel. Preliminary experiments are conducted to study the effect of machining parameters on surface roughness. Voltage, duty factor, frequency and tool feed rate are identified as the significant factors for controlling surface roughness of the channels produced by G-ECDM. A mathematical model was developed for surface roughness by considering the grinding action and thermal effects of electrochemical discharges in material removal. Experiments are conducted to validate the model and the results obtained are in good agreement with that predicted by the model.

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Section: E = I (T)v (T)dtmentioning

confidence: 99%

A mathematical model for surface roughness of fluidic channels produced by grinding aided electrochemical discharge machining (G-ECDM)

Ladeesh

Manu

2017

MATEC Web Conf.

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“…The effect of wettability of electrodes on the process has also been explained with the help of a model [20]. A finite element model has been developed to predict the machining depth of the process up to 300 μm [21]. Such models have also been used to predict the material removal rate of the process [22].…”

Section: Literature Reviewmentioning

confidence: 99%

A mathematical model to predict overcut during electrochemical discharge machining

Kamaraj

Jui

Cai

et al. 2015

Int J Adv Manuf Technol

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Overcut is a major reason for the dimensional deviations, especially during high aspect ratio micromachining in electrochemical discharge machining (ECDM). Since electrolyte concentration plays a vital role in material removal, by understanding the effect of electrolyte concentration on the machined feature, it is possible to reduce the overcut associated with the ECDM process. This reduction in overcut was used in the study to drill high aspect ratio microholes in glass. The effect of concentration on the overcut is explained with an analytical model. The model considers the thermal effects on material removal for ECDM assuming a high-temperature chemical etching mechanism for the material removal. It describes the effect of electrolyte concentration as well as machining time on material removal. Results reveal that at the microscale, tool diameter has minimal effect on overcut for a given machining voltage. Microholes with aspect ratios as high as 12 were produced in glass in this study.

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“…To make the modeling procedure mathematically traceable, the following assumptions which have been frequently considered in ECDM modelling [16,18,19] were taken into account:…”

Section: Modeling Of Materials Removal In Ecdm Processmentioning

confidence: 99%

“…They concluded that 600 ºC can be considered as the machining temperature in ECDM of glass. Wei et al [19] also proposed a model for prediction of the material removal rate in discharge regime. They also assumed that the spark diameter is 300 µm as measured by Kulkarni et al [17].…”

Section: Introductionmentioning

confidence: 99%

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Experimental and Numerical Study of Material Removal in Electrochemical Discharge Machining (ECDM)

Behroozfar

Razfar

2015

Materials and Manufacturing Processes

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In this paper a novel approach is proposed to investigate the characteristics of the plasma channel and material removal in electrochemical discharge machining (ECDM) of glass.For this purpose, a specific pulsed voltage was applied to the ECDM process to perform single discharging on the glass workpiece. In this way, a voltage slightly lower than the critical voltage was applied as the offset voltage. Meanwhile the working voltages above the critical voltage were applied to the process in a specific period of time to produce single sparks. The signatures of the single sparks on the workpiece surface were used to determine the characteristics of the plasma channel. According to the results, the average diameter of 260 µm was achieved for the plasma channel in the glass machining conditions. This paper also reports a thermo-physical model for material removal in ECDM process based on the finite element method (FEM) and plasma channel diameter achieved in this study. The amount of the removed material as well as the diameter and depth of the crater, achieved by the FEM, was measured and compared with the experimental outcomes. The results demonstrate the consistency of the proposed model with the experimental observations.

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A finite element based model for electrochemical discharge machining in discharge regime

Cited by 62 publications

References 19 publications

A mathematical model for surface roughness of fluidic channels produced by grinding aided electrochemical discharge machining (G-ECDM)

A mathematical model for surface roughness of fluidic channels produced by grinding aided electrochemical discharge machining (G-ECDM)

A mathematical model to predict overcut during electrochemical discharge machining

Experimental and Numerical Study of Material Removal in Electrochemical Discharge Machining (ECDM)

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