Development of a Thermo-Physical Model for Multi-spark Wire EDM Process

Shahane, Shantanu; Pande, S.S.

doi:10.1016/j.promfg.2016.08.019

Cited by 28 publications

(7 citation statements)

References 17 publications

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“…Plethora of research study and analyse this phenomenon; mathematical models are developed to provide better understanding of the EDM process. A quasi-static model is proposed by [146], the model computes the material removal rate based on predicted distribution of the temperature in the workpiece. Equation of transient heat conduction is employed to predict the distribution.…”

Section: General View Of the Edm Methodsmentioning

confidence: 99%

Advanced Electric Discharge Machining of Stainless Steels: Assessment of the State of the Art, Gaps and Future Prospect

et al. 2019

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Electric discharge machining (EDM) is a material removal process that is especially useful for difficult-to-cut materials with complex shapes and is widely used in aerospace, automotive, surgical tools among other fields. EDM is one of the most efficient manufacturing processes and is used to achieve highly accurate production. It is a non-contact thermal energy process used to machine electrically conductive components irrespective of the material’s mechanical properties. Studies related to the EDM have shown that the process performance can be considerably improved by properly selecting the process material and operating parameters. This paper reviews research studies on the application of EDM to different grades of stainless steel materials and describes experimental and theoretical studies of EDM that have attempted to improve the process performance, by considering material removal rate, surface quality and tool wear rate, amongst others. In addition, this paper examines evaluation models and techniques used to determine the EDM process conditions. This review also presents a discussion on developments in EDM and outlines the likely trend for future research.

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Section: General View Of the Edm Methodsmentioning

confidence: 99%

Advanced Electric Discharge Machining of Stainless Steels: Assessment of the State of the Art, Gaps and Future Prospect

et al. 2019

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“…Also, the increased working temperature of the dielectric liquid during WEDM has negative effects, by decreasing the geometrical accuracy of the machined surface. This undesirable effect is described in detail by Shahane and Kapoor [11,12], and the solution of this problem is considered to be the application of a low-temperature machining mode with cooling of a dielectric fluid. In this context, Singh stresses the need to take account of the heat load at the point of electric discharge by a suitable choice of working gap flushing intensity [13].…”

Section: Introductionmentioning

confidence: 99%

Prediction of the Geometrical Accuracy of the Machined Surface of the Tool Steel EN X30WCrV9-3 after Electrical Discharge Machining with CuZn37 Wire Electrode

Straka

Čorný

Piteľ

2017

Metals

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Abstract:The geometrical accuracy of the machined surface can generally be understood mainly as accuracy of shape, orientation, position and run-out. As a general rule; it is quantified by the corresponding deviations from the nominal area. The size of the geometric deviation from the nominal area may in practice affect the conventionally measured value of the dimension, even if the required dimensional tolerance is adhered to. Since electro-erosive machining technology belongs to very precise finishing technologies; even the small geometrical accuracy deviation has a negative impact on the resulting quality of machined surfaces. The aim of the experiments was to contribute to the knowledge database, which defines the influence of the process parameters at electrical discharge machining with the CuZn37 tool electrode on errors of geometrical accuracy of the machined surface. On the basis of the results of the experimental measurements, graphical dependencies were determined which predict geometrical accuracy of the machined surface in terms of the maximum deviation of flatness after electrical discharge machining of tool steel EN X30WCrV9-3 (W.-Nr. 1.2581) with CuZn37 wire electrode of 0.20 mm diameter to determine the appropriate combination of process parameters.

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“…In finite element modeling and the simulation of EDM, two categories exist: singlespark simulations and multi-spark simulations. Shahane and Pande [65] introduced an innovative approach for simulating the occurrence of multiple sparks with overlapping craters by modifying the transient heat transfer model originally designed for single sparks. In multi-spark simulations, EDM is conducted through a sequence of single-spark events.…”

Section: Multi-spark Simulationsmentioning

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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Development of a Thermo-Physical Model for Multi-spark Wire EDM Process

Cited by 28 publications

References 17 publications

Advanced Electric Discharge Machining of Stainless Steels: Assessment of the State of the Art, Gaps and Future Prospect

Advanced Electric Discharge Machining of Stainless Steels: Assessment of the State of the Art, Gaps and Future Prospect

Prediction of the Geometrical Accuracy of the Machined Surface of the Tool Steel EN X30WCrV9-3 after Electrical Discharge Machining with CuZn37 Wire Electrode

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

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