Numerical simulation of micro-EDM model with multi-spark

Somashekhar, K. P.; Panda, Satyananda; Mathew, Jose; Ramachandran, N.

doi:10.1007/s00170-013-5319-9

Cited by 49 publications

(20 citation statements)

References 31 publications

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“…During μ-EDM, it has been reported [30,31] that the material is transferred among the electrodes. The same phenomenon has happened in the single-spark crater.…”

Section: Model Validation With Experimental Resultsmentioning

confidence: 99%

“…This sudden removal of plasma pressure results in cavitation effect and removes molten metal from the electrode surfaces. Due to high plasma pressure and cooling effect of dielectric, some molten materials remain as recast layer on the machined surface [30].…”

Section: Electrothermal Model Of μ-Edmmentioning

confidence: 99%

“…There are many different numerical methods that have been presented in the past for this kind of analysis (e.g., [8,10,11,13]), and in this paper, we mostly follow the finite volume technique described in Somashekar et al [30] for the twodimensional model and extend this approach to three dimensions. The governing Eq.…”

Section: Solution Proceduresmentioning

confidence: 99%

“…to predict the shape of crater cavity. They have extended this approach with multispark numerical model based on two-dimensional finite volume method [30] and predicted the effect of spark ratio on the temperature distribution in the workpiece. However, the analysis presented by the authors is limited to a two-dimensional model and it demands numerical investigation of full three-dimensional model.…”

Section: Introductionmentioning

confidence: 99%

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Three-dimensional numerical simulation of microelectric discharge machining of Ti-6Al-4V

Kuriachen

Varghese

Somashekhar³

et al. 2015

Int J Adv Manuf Technol

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The aim of the present work is to develop a predictive thermal model based on heat transfer principle for the simulation of single-spark microelectric discharge machining (μ-EDM). The three-dimensional model is solved using finite volume method (FVM). It utilizes the Gaussian distribution of heat flux, percentage distribution of energy among the workpiece, tool electrode, and dielectric to perform transient thermal analysis to predict the crater geometry and temperature distribution in the workpiece at different voltages and capacitance values along the x, y, and z directions. The experiments were performed for single-spark discharge using a resistorcapacitor (RC) circuit with titanium alloy (Ti-6Al-4V) as workpiece material and tungsten carbide as tool electrode. The experimental crater dimensions were measured by using a scanning electron microscope (SEM). The model is validated by comparing the predicted temperature distribution with the published results and also with experimental results. Results show that the trends predicted by the model are logical and match fairly well with the experimental trends.

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“…During μ-EDM, it has been reported [30,31] that the material is transferred among the electrodes. The same phenomenon has happened in the single-spark crater.…”

Section: Model Validation With Experimental Resultsmentioning

confidence: 99%

Section: Electrothermal Model Of μ-Edmmentioning

confidence: 99%

Section: Solution Proceduresmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Three-dimensional numerical simulation of microelectric discharge machining of Ti-6Al-4V

Kuriachen

Varghese

Somashekhar³

et al. 2015

Int J Adv Manuf Technol

Self Cite

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“…Hui et al [10] developed a discharge model to analyze the influence of electrodes on the formation and expansion of the discharge channel, and the model was verified by monopulse discharge experimental results. By considering a constant spark radius and Gaussiandistributed heat flux, Somashekhar et al [11] proposed a numerical model based on finite volume method for the multispark analysis of micro-EDM. The model was validated by comparing the calculated results to those obtained by Murali et al [12].…”

Section: Introductionmentioning

confidence: 99%

A new thermal model considering TIE of the expanding spark for anode erosion process of EDM in water

Zhang

et al. 2015

Int J Adv Manuf Technol

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For the advantages of environment-friendly decomposition product, fireproofing, and low cost, the water or water-based dielectric is widely used in die-sinking electrical discharge machining (EDM) and wire EDM, especially in the high-efficiency electrical erosion process. In order to study the process of EDM in water, in this paper, a theoretical spark column expansion formula has been derived instead of directly using the previous empirical expressions for EDM in oil dielectric. It is found that the approximate expression of the proposed formula is extremely close to the previously widely used empirical expression for EDM in oil dielectric when the parameters are selected appropriately. The corresponding parameters for EDM in water are determined according to the dimensions of experimentally obtained craters. The proposed theoretical formula reveals that the total heat transfer time decreases radially from the center to the periphery at the spark/anode interface rather than equals to the pulse on time everywhere. This phenomenon can be considered as the time integration effect (TIE) caused by the expanding spark, and it has been calculated quantitatively based on the derived formula. Finally, a finite element thermal model considering the TIE has been developed. The results of craters and material removal rate (MRR) predicted by the proposed model show a close agreement with experimental results, which indicates that the developed thermal model can be used to study the spark expansion rule and understand the EDM process. Keywords Electrical discharge machining (EDM) . Spark expansion formula . Finite element thermal model . Time integration effect (TIE) Nomenclature C Combined coefficient (μm 2 /J) C p Average specific heat (J/kg/K) K Average thermal conductivity (W/m/K) i Peak current (A) u Discharge maintaining voltage (V) t e Pulse on time (μs) t off Pulse off time (μs) t h Total heat transfer time (μs) R s Spark column radius (μm) lDistance of discharge gap (μm) r i Initial spark radius (μm) R c Crater radius (μm) h c Crater depth (μm) V c Volume removed per spark (mm 3 ) F a Fraction of energy going to anode T m Melting Temperature (K) T b Boiling Temperature (K) L m Latent heat of melting (kJ/kg) L v Latent heat of vaporization (kJ/kg) T Temperature (K) q 0 Uniform heat flux (W/m 2 ) ρAverage material density (kg/m 3 )

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