Application of CFD and vapor bubble dynamics for an efficient electro-thermal simulation of EDM: an integrated approach

Das, Shirsendu; Paul, Swarup; Doloi, B.

doi:10.1007/s00170-018-3144-x

Cited by 16 publications

(3 citation statements)

References 28 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Salah et al adopted a numerical simulation method to simulate the heat flux and temperature distribution and represented graphically the variation in roughness and erosion rate with input current [79,80]. Das et al [81] performed an electrothermal simulation of EDM process, where the concept of vapor bubble dynamics and CFD were included for more precise predictions. Findings claimed that flushing has a significant consequence and 31-33.5% of the total discharge is dissipated by flushing.…”

Section: Dielectric Heat Dissipationmentioning

confidence: 99%

Feasibility assessment of some alternative dielectric mediums for sustainable electrical discharge machining: a review work

Das

Paul

Doloi

2020

J Braz. Soc. Mech. Sci. Eng.

Self Cite

View full text Add to dashboard Cite

Low removal rate, high power consumption, and dependency on conventional fuels (kerosene as a dielectric) are some premier issues that keep the sustainability index of EDM low, though it has huge acceptability and popularity mostly in aviation sectors and biomedical instrumentation to machine some extensively hard ferrous and nonferrous metal/metal alloys. Besides these, the thermal agitation inside the fusion/machining zone partially burns the dielectrics and tool-workpiece-metal, which evolve some oxides/monoxides. These evolved gases promote an unhygienic breathing atmosphere, which is very much harmful to the operator's health. Sometimes because of inadequate flushing pressure and velocity, carbon particles deposited inside the crater makes the spark unstable and releases carbon monoxide when the temperature exceeds its melting point. According to ISO 14000, every manufacturing process must be comprised of the sustainability criteria, which maintains a compromised balance between the economic, environmental, and social aspects, including the issue of the operator's health. But in real practices, it is very tough to maintain a stoichiometric balance between all these constraints. The article intensely focuses on the issue of emergence of gases during machining and tries to promote the utility of some alternative vegetable oil-based dielectrics, which are experimentally justified as a potent alternative of conventional kerosene. Apart from these, it includes some comparative talks on dielectric nature and their impacts on the responses and surface properties. Finally, this article highlights some compromise solutions which are probably capable of mitigating the hurdles to some extent, so that the sustainable machining can be encouraged in real sense.

show abstract

Section: Dielectric Heat Dissipationmentioning

confidence: 99%

Feasibility assessment of some alternative dielectric mediums for sustainable electrical discharge machining: a review work

Das

Paul

Doloi

2020

J Braz. Soc. Mech. Sci. Eng.

Self Cite

View full text Add to dashboard Cite

show abstract

“…In terms of theoretical simulations, researchers have also made some findings. Das et al [13] investigated the dynamic behavior and heat dissipation of a dielectric fluid through a plasma channel by using an integrated approach of vapor bubble dynamics and computational fluid dynamics, with a model accuracy of more than 95%, and with a high degree of confidence in the model results. Zhang et al [14] performed a three-dimensional evolution of the discharge-generated bubbles in three dimensions and found that when the interpolar distance was small and a greater force was applied on the workpiece or tool electrode, it would help to accelerate bubble expansion.…”

Section: Introductionmentioning

confidence: 99%

Analysis of mechanisms of bubble characteristics and molten pool dynamics in EDM based on a three-phase flow model

Peng,

Tang,

et al. 2024

J. Phys. D: Appl. Phys.

View full text Add to dashboard Cite

Bubble characteristics and bubble volume fraction have significant effects on crater morphology and machining efficiency during EDM in liquid. Therefore, there is a need to elucidate the mechanism of bubble characteristics in EDM and analyze the mechanism of crater formation based on these bubble characteristics. However, since EDM is a transient multiphysics process, it is extremely challenging to understand the bubble characteristics by experimental methods. Therefore, the generation, expansion, explosion, and disappearance of bubbles during EDM were simulated based on a three-phase flow model in this study. The model used the phase field method to track the boundary motion, judged the existence mode of each phase according to the order parameter gradient function, and analyzed the formation of crater morphology by the gradient of surface tension in the molten pool. The motion process of bubbles, the material removal mode, and the formation mechanism of crater morphology during the pulsed discharge were analyzed by the model. The results revealed that the periodic motion of the plasma channel would drive the molten pool to produce the corresponding periodic motion, and the bubbles would grow following the periodic motion of the molten pool. The material was removed in different ways in different periods, among which the removal mode of molten splash was the predominant. The surface tension gradient inside the molten pool, the periodic motion of the molten pool, and the hydrostatic pressure in the molten region had a combined effect on the bubble motion, the flow of the molten pool, and the formation of the crater morphology.

show abstract

“…Wang and Han (2014) using a three-phase RANS approach. Recently, the heat transfer and the heat dissipation rate of the dielectric fluid were investigated by Das et al (2019) using a three-dimensional fluid simulation with a state-of-the-art bubble-dynamics model that takes material vaporization into account. The erosion, ejection, and solidification processes in EDM were simulated by Zhang et al (2019).…”

Section: Introductionmentioning

confidence: 99%

Direct particle–fluid simulation of flushing flow in electrical discharge machining

Gadeschi

Schilden

Albers

et al. 2021

Engineering Applications of Computational Fluid Mechanics

View full text Add to dashboard Cite

The efficient removal of material debris by flushing is critical for the performance and the surface quality of the electrical discharge machining (EDM) manufacturing process. The particle concentration alters the thermal, mechanical, and electrical properties of the particle-dielectricum suspension and affects the manufacturing process and the surface quality by inducing high thermal loads. For the first time, we perform a direct particle-fluid simulation of the flushing cycle in a generic EDM cavity using a hierarchical Cartesian sharp-interface cut-cell method. The flow around each debris particle is completely resolved and the heat transfer between the particles and the fluid is taken into account. The rate of material removal and the cooling performance of the flushing mechanism are studied for three-volume loadings. The results show that the flow around the particles has a pronounced impact on the heat transfer between the dielectricum and the workpiece. A particle loading of 14% increases the mean heat transfer by approximately 16%. The particle loading also has a pronounced impact on the rate at which particles are flushed out of the cavity. Increasing the initial volume loading from 6% to 14% decreases the amount of particles that get flushed out of the cavity by 14%.

show abstract

Application of CFD and vapor bubble dynamics for an efficient electro-thermal simulation of EDM: an integrated approach

Cited by 16 publications

References 28 publications

Feasibility assessment of some alternative dielectric mediums for sustainable electrical discharge machining: a review work

Feasibility assessment of some alternative dielectric mediums for sustainable electrical discharge machining: a review work

Analysis of mechanisms of bubble characteristics and molten pool dynamics in EDM based on a three-phase flow model

Direct particle–fluid simulation of flushing flow in electrical discharge machining

Contact Info

Product

Resources

About