A novel thermo-hydraulic coupling model to investigate the crater formation in electrical discharge machining

Tang, Jiajing; Yang, Xiaodong

doi:10.1088/1361-6463/aa7bb7

Cited by 43 publications

(22 citation statements)

References 22 publications

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“…1. This is undesirable to researches on geometric parameters such as dimension and residual stress of craters [17,18]. Fortunately, this study focuses on the material removal and residual volume per discharge, as well as the moving tendency of molten material in fast ED-milling, if the number of discharges occurring during an experiment can be accurately counted, these evaluation indicators can be obtained more meaningfully.…”

Section: Methodsmentioning

confidence: 99%

Experimental and numerical investigation into material removal mechanism of fast ED-milling

Wang

Chu

et al. 2022

Int J Adv Manuf Technol

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Fast electrical discharge milling (Fast ED-milling) has become a promising technology in the manufacturing industry for machining complex structures such as diffuser-shaped lm cooling holes. However, the mechanism of the e cient removal of materials in this technology is not yet fully understood. To gain a further insight into this matter, an experimental investigation on the morphology of discharge craters including the absolute material removal volume per discharge, material residual volume per discharge, and directionality, is rstly carried out. The obtained results imply that a high-pressure inner ushing can signi cantly promote the expelling of molten material from a molten pool and is a fundamental reason why fast ED-milling can be of higher machining e ciency than regular ED-milling.To explore the mechanism behind, a novel thermal-uid coupling model is developed to simulate the evolution process of the molten material under the effect of a ow eld. The results of numerical simulation show that during a discharging, the molten material moves along the workpiece surface towards the outlet of a gap channel and solidi es at the side of a crater that is away from the electrode center. Another interesting nding is that an inappropriately high ushing pressure can result in a low machining e ciency because the severe heat convection will consume a large part of the heat generated by a discharge. This well explains the phenomenon that occurred during the experimental investigation.

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Section: Methodsmentioning

confidence: 99%

Experimental and numerical investigation into material removal mechanism of fast ED-milling

Wang

Chu

et al. 2022

Int J Adv Manuf Technol

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“…In the plasma channel, due to the high-speed movement of electrons, charged ions collide with each other, generating a large amount of heat, melting the electrode, part of the electrode and the working fluid vaporize, and the volume expands rapidly [ 22 ]. The resulting pressure gradient causes molten metal and vaporized metal to peel from the electrode surface and enter the working fluid [ 23 ].…”

Section: Numerical Methodology and Experimental Methodsmentioning

confidence: 99%

The Numerical and Experimental Investigation of Particle Size Distribution Produced by an Electrical Discharge Process

Lin

Liu

et al. 2021

Materials

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The vague influence of thermal action of electrical discharge on size distribution of metallic powders hinders the adjustability of powder quality. Due to the small gap, short discharge on-time, uncertain discharge point, and strong light interference, direct observation of preparation is difficult to carry out. Herein, the multi-physics coupling finite element method (FEM) was applied to numerically investigate the relationship between size distribution and thermal action. Through modeling of thermal transformation and heat distribution on the surface of electrode, temperature of the electrode is found to be decided by the latent heat and the distribution of heat point obeys the normal distribution, which corresponds with experimental results. Finally, the vapor film to droplet fragmentation theory was proposed to explain the phenomenon of normal distribution. The research results provide theoretical support for the preparation of metallic powder by electrical discharge, and also play a guiding role in optimizing the process parameters in the actual preparation process to tune the size distribution.

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“…The electrical discharge machining modelling resorts to a series of distinct models. Amongst these, there is a large number of thermal models [ 3 , 4 , 5 , 6 ], very few thermal–electrical models [ 7 , 8 ] and only one thermal–hydraulic model [ 9 ]. As far as thermal models are concerned, different sources of heat are used, such as the point heat source, the disc heat source, and Gaussian heat distribution source.…”

Section: Introductionmentioning

confidence: 99%

Analysis of EDM Performance, through a Thermal–Electrical Model with a Trunk-Conical Discharge Channel, Using a Steel Tool and an Aluminium Workpiece

et al. 2021

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In this article, a finite element (FE) thermal–electrical model with a trunk-conical discharge channel is employed to simulate individual EDM discharges with a time-on of 18 μs up to 320 μs, which are subsequently compared with the experimental results to validate the model. The discharge channel is a trunk-conical electrical conductor which dissipates heat by the Joule heating effect, being the correspondent factor equal to 1. Instead of the usual copper–iron electrode combination, steel (DIN CK45) and aluminium alloys (DIN 3.4365) are the implemented materials on both the tool and the workpiece, respectively. The numerical results were measured using the melting temperature of the materials as the boundary of material removal. The results obtained with the thermal–electrical model, namely the tool wear ratio, the tool wear rate, the material removal rate, and the surface roughness, are in good agreement with experimental results, showing that the new FE model is capable of predicting accurately with different materials for the electrodes.

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A novel thermo-hydraulic coupling model to investigate the crater formation in electrical discharge machining

Cited by 43 publications

References 22 publications

Experimental and numerical investigation into material removal mechanism of fast ED-milling

Experimental and numerical investigation into material removal mechanism of fast ED-milling

The Numerical and Experimental Investigation of Particle Size Distribution Produced by an Electrical Discharge Process

Analysis of EDM Performance, through a Thermal–Electrical Model with a Trunk-Conical Discharge Channel, Using a Steel Tool and an Aluminium Workpiece

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