A thermophysical modelling of electric discharge coating process

Abstract

This research paper presents a thermophysical model development and simulation of the electric discharge coating process (EDC). Many literatures are available for the electric discharge coating process from an experimental perspective. A 2-D axisymmetric model was initially developed with the realistic assumption with multi-spark overlap conditions considered in this work. The melt pool volume of the tool material is estimated from the 2D model. The 3D coating model was developed using COMSOL Multiphysics 5.4. This model predicts the temperature distribution on the green compact tool electrode and coating thickness on the substrate. To validate the simulation model, the experimental result from the literature is compared with the simulation result. The simulation and validation trials results reveal that the present developed coating model can predict the coating thickness with minimum error (4% -14%). The developed multi-spark model for the EDC process can be referenced to understand the coating mechanism for various tools and workpiece materials.

Development and analysis of solid lubricant coating on M2 high-speed steel using the EDC process

“…It is observed that when the current increases, coating thickness increases. The plasma radius and melt pool volume depend on power density at the tool surface [15]. So, an increase in current enhances tool wear and material deposition rate.…”

“…Muralidharan B et al [14] analyzed the relation between the input process parameters and the response of the EDC process with empirical and mathematical models. Kumaran V et al [15] developed a thermophysical model with COMSOL Multiphysics for the EDC process to understand the mechanism of the coating process. Solid lubricants are applied in harsh conditions with high vacuum and elevated temperature.…”

Electric discharge coating process: a critical review with potential application

“…Algodi SJ et al [29] developed a single spark modelling to analyze the EDC process on crater formation and the transfer of heavy species material from the tool electrode. Kumaran V et al [30] developed a thermophysical model to analyze the EDC mechanism with multi-spark phenomena and reported an error factor of coating thickness between a range of 4% to 14% compared to experimental studies.…”

Analysis of adhesion strength and residual stresses developed by the EDC process

“…Lee C et al [30] detailly investigate the effectiveness of nitride coating on steel substrates by scratch test and the result shows that coated substrates have better tribological properties. Kumaran V et al [31] developed a simulation model to better understand the coating phenomenon in the electric discharge coating process. This model showed that both the pulse duration and current had a significant impact on the coating thickness.…”