Modeling of the temperature field induced during electrical discharge machining

Schneider, Sebastian; Herrig, T.; Klink, Andreas; Bergs, Thomas

doi:10.1016/j.cirpj.2022.05.012

Cited by 9 publications

(4 citation statements)

References 36 publications

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“…Its characteristics directly affect the heating state of the discharge point and are the most direct factor affecting the discharge erosion. Therefore, it is necessary to conduct in-depth research on the channel [18] . During each single spark discharge process, various complex reactions occur.…”

Section: Theoretical Calculation Of Discharge Channelsmentioning

confidence: 99%

“…The additional forces introduced in the physical layer of laminar flow simulation encompass: During the phase transition of the electrode material, both the solid-phase region, liquidphase region, and the coexistence of both phases occur simultaneously. To better track the physical state of these regions during the simulation, a porous media model [18] is employed to establish equations addressing this issue. Darcy resistance is utilized to set up its equation.…”

Section: ) Laminar Flow Modulementioning

confidence: 99%

“…Zhi-Wei Liu et al [16] segmented the EDM process into two stages, exploring temperature gradients using Comsol during the heating phase and utilizing Micress for microstructural evolution in the post-discharge re-melting phase. R.Hess et al [17] extended existing heat transfer models to obtain actual temperature gradients for single discharges in the EDM process, calculating temperature gradients to simulate the evolution of 42CrMo4 steel structures [18] . Despite finite element models establishing thermal loads, insufficient depth was explored in Comsol's boundary conditions and re-melting layer thickness.…”

Section: Introductionmentioning

confidence: 99%

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Simulation research on the thermal phase transition of EDM and the formation mechanism of remelted layer in single pulse spark discharge crater

Chen,

Liu,

Luo

et al. 2024

Preprint

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The remelted layer formed by the Electrical Discharge Machine(EDM)impacts surface quality of small hole and significantly reduces the fatigue life of workpieces. Based on Comsol Multiphysics ,this paperusessimulates the formation process of the remelted layer under single-pulse condition. When horizontal set and two-phase flow methods are used to track the phase interface, the model is built under the coupling of flow and heat transfer fields, which simulates the solid-liquid-gas transformation during discharge etching via porous medium and weak expression methods. The simulation results show that the temperature rapidly decreases from the midpoint of the discharge center axis to the surrounding area, and the radius of the plasma region is 95.3 µm. The diameter of the pit is 108.5 µm. The thickness of the remelted layer is 16 µm. The thickness of the remelted layer obtained from experiments under the same conditions is 16.4um. The comparison shows that the difference between the two is small, indicating that the simulation model can accurately predict the thickness of the remelted layer, providing a new approach for evaluating the thickness of the remelted layer in EDM.

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Section: Theoretical Calculation Of Discharge Channelsmentioning

confidence: 99%

Section: ) Laminar Flow Modulementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Simulation research on the thermal phase transition of EDM and the formation mechanism of remelted layer in single pulse spark discharge crater

Chen,

Liu,

Luo

et al. 2024

Preprint

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“…Kliuev et al[33] used a similar function with the addition of a second constant term which could be determined by an optimization procedure. Schneider et al [34] also employed a function with a second constant term, which was dependent on maximum spark radius, initial radius and discharge duration. In every case where power law was adopted, the exponent has values below 1.0.…”

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

Papazoglou

Karmiris-Obratański

Karkalos

et al. 2023

Int J Adv Manuf Technol

View full text Add to dashboard Cite

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.

show abstract

Modeling of the temperature field induced during electrical discharge machining

Cited by 9 publications

References 36 publications

Simulation research on the thermal phase transition of EDM and the formation mechanism of remelted layer in single pulse spark discharge crater

Simulation research on the thermal phase transition of EDM and the formation mechanism of remelted layer in single pulse spark discharge crater

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

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

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