A novel approach to plasma channel radius determination and numerical modeling of electrical discharge machining process

Gholipoor, Ahad; Shabgard, Mohammad Reza; Mohammadpourfard, Mousa

doi:10.1007/s40430-020-2244-3

Cited by 16 publications

(5 citation statements)

References 26 publications

(30 reference statements)

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“…Because, the influence time of the total energy to the workpiece by working current extends by increasing of pulse-on time. In longer pulse durations, the plasma has enough time to increase its radius with an increase in pulse duration, as determined in lots of study [28]. However, the short pulses cause less vaporization from the workpiece and long pulses cause the plasma channel to expand.…”

Section: The Effects Of the Electrical Parameters On Mrrmentioning

confidence: 97%

Application of multi-criteria decision-making (MCDM) methods on a meso-scale electrical discharge drilling (EDD) process

Yıldız

2020

SN Appl. Sci.

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Multi/Multiple-criteria decision-making methods or multiple-criteria decision analysis (MCDA) have a useful contribution to determine the optimal or the best experimental condition for a process. One of the objectives of the presented research is the observation of the effects of the electrical parameters on the material removal rate (MRR) and the electrode wear ratio (EWR) in a meso-scale EDD. The examined electrical parameters are pulse-on/off time, duty cycle/factor and capacitance. Machining results have been investigated by analysis of variance and graphically depending on their main effects. While pulse-on time and duty cycle have statistically significant effect on MRR, pulse-on time, capacitance and duty cycle have significant effect on EWR for the EDD processes. VIKOR, TOPSIS (Technique for Order Preference by Similarity to Ideal Solution) and GRA (Grey Relation Analysis) were used as MCDM methods to determine the optimum machining result in terms of maximum MRR and minimum EWR. MCDM results have been monitored by graphically. Since an inconsistency has been seen between the MCDM results, a second supplementary analysis has been done by Weighted of Sum and Weighted of Product methods. By this way, a better consistency has been provided. Consequentially, it has been seen that the results of the second modifier analysis and the results of VIKOR were closer to each other in terms of specifying the optimal condition for the process. Hole formations were also observed by scanning electron microscopy images in this work. As a result, it has been decided that the minimum pulse-on time and pulse off-time with 50% duty cycle and minimum capacitance inputs gives an optimum output for MRR and EWR in the meso-scale EDD process.

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Section: The Effects Of the Electrical Parameters On Mrrmentioning

confidence: 97%

Application of multi-criteria decision-making (MCDM) methods on a meso-scale electrical discharge drilling (EDD) process

Yıldız

2020

SN Appl. Sci.

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“…Especially for magnetic eld-assisted EDM process, Shabgard et al [29] also used a slightly modi ed model of their original one, including the effect of the additional magnetic eld in the differential equation of plasma expansion. Gholipoor et al [30] compared the results of the model presented by Shabgard et al [28] and showed that the calculated plasma radius values are slightly higher to those of semi-empirical models.…”

Section: Shabgard Et Almentioning

confidence: 99%

Theoretical and experimental analysis of plasma radius expansion model in EDM: a comprehensive study

Papazoglou¹,

Karmiris-Obratański

Karkalos³

et al. 2023

Preprint

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Electrical Discharge Machining (EDM) is an established non-conventional process, which is particularly efficient for the processing of hard-to-cut materials, in order to obtain high dimensional accuracy and surface integrity. However, in order to determine the appropriate parameters for machining novel materials, it is necessary to investigate the EDM process in depth, both by experiments and numerical models, taking into consideration the fundamental physical phenomena occurring during this process and be able to predict the surface morphology and microstructural alterations under various conditions. One of the challenging issues of EDM simulation models that still remain open is the representation of the evolution of plasma channel radius, for which various approaches have been proposed such as a linear, power law or a more complex piecewise relation, in respect to time. Thus, in this work, the effect of different relations for the plasma channel radius evolution on energy absorption coefficient, Plasma Flushing Efficiency (PFE) and crater morphology is compared under various conditions with a numerical model, which is also compared to experimental data. The results indicate that the energy absorption coefficient is dependent on the plasma column radius function, as slower growth of plasma channel leads to lower absorption coefficient and more efficient material removal, whereas a lower variation and different trends under different conditions were observed regarding PFE values, in respect to the power law exponent. Finally, the crater dimensions were shown to be consistently more narrow and deeper with higher exponents, thus based on actual observations of indicative craters, it was revealed that the appropriate values for the exponent of the power law plasma radius function are below 0.25.

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“…Figure 5a illustrates a noteworthy rise in the depth of the indentation, attributable to a rise in the duration of pulsation, aligning with an escalation in the thickness of the layer. Gholipoor et al [64] conducted a finite element simulation of the single-spark discharge process in EDM. They utilized a numerical model to investigate the effects of pulse current and duration as input parameters on the RLT of molten material in machined surface craters.…”

Section: Recast Layer Thicknessmentioning

confidence: 99%

Progress in Simulation Modeling Based on the Finite Element Method for Electrical Discharge Machining

Li,

Sun,

Xing

et al. 2023

Metals

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Electrical Discharge Machining (EDM) is a machining method commonly used to produce complex shapes and deep holes by eroding hard metals with an electric arc. There is a growing demand for process simulation using finite element models in order to improve the quality and efficiency of EDM, to reduce costs, to improve resource efficiency, and to facilitate its application in critical areas such as aerospace and mechanical engineering. Finite element models have greatly improved the prediction accuracy of EDM processes, simulated complex hybrid machining processes, and provided important guidance for the optimization of EDM processes. This paper systematically reviews the research progress of finite element modeling for EDM. Finite element method modeling is evaluated mainly in terms of four indicators: material removal rate, surface roughness, tool wear ratio, and recast layer thickness. Firstly, the importance and application of EDM are described, and the EDM finite element method modeling and its advantages are summarized. Then, the single-spark simulation model and the multi-spark simulation model of EDM are compared and discussed. Among the mainstream finite element models, the prediction error of the material removal rate for single-spark simulation ranges from 8.2% to 14.75%, while the prediction error of the recast layer thickness for multi-spark simulation can be as low as 1.98%. Finally, the applications of finite element modeling in EDM hybrid machining processes’ performance prediction and new material machining are summarized, and future research directions and trends in EDM finite element modeling are predicted.

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A novel approach to plasma channel radius determination and numerical modeling of electrical discharge machining process

Cited by 16 publications

References 26 publications

Application of multi-criteria decision-making (MCDM) methods on a meso-scale electrical discharge drilling (EDD) process

Application of multi-criteria decision-making (MCDM) methods on a meso-scale electrical discharge drilling (EDD) process

Theoretical and experimental analysis of plasma radius expansion model in EDM: a comprehensive study

Progress in Simulation Modeling Based on the Finite Element Method for Electrical Discharge Machining

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