Thermo-fluid multi-physics modeling and experimental verification of volumetric workpiece material removal by a discharge pulse in electric discharge machining process

Erdem, Oğuz; Çoğun, Can; Uslan, Ibrahim; Erbas, Murat

doi:10.1088/1361-6463/ab9573

Cited by 5 publications

(2 citation statements)

References 70 publications

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“…Multi-spark simulations offer several advantages over single-spark simulations, including enhanced realism, accuracy, the capability to simulate intricate machining processes, improved simulation precision, and broader applicability. However, due to variations in the position and pressure of dielectric media, such as bubbles and solid particles within the gap, which change with time and location, it is not possible to obtain the result of multiple discharges through a simple linear superposition of individual discharge outcomes [67,68]. Therefore, the study of multi-spark simulations is crucial.…”

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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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

View full text Add to dashboard Cite

show abstract

“…Tang et al [19][20][21] simulated the formation of discharge craters, which distinguished a recast layer based on the surface temperature after discharging. Erdem et al [22] focused on the material removal and the formation of a re-solidified layer in EDM by building a multi-physics model with ANSYS CFX software. Wang et al [23] used the Fluent software to simulate a fast EDM drilling process.…”

Section: Introductionmentioning

confidence: 99%

Study on the evolution process of recast layer for fast EDM drilling based on observation experiment and a novel thermal-fluid coupling model

Chu

et al. 2021

J. Phys. D: Appl. Phys.

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The existence of a recast layer of film cooling holes on turbine blades imposes a crucial problem that affects the quality of fast electrical discharge machining (EDM) drilling. This paper focuses on an evolution process from molten material generation to recast layer formation. Single pulse discharge observation experiments with a high speed camera and a self-built observation platform were carried out to observe the formation and movement of the molten material. A novel thermal-fluid coupling model is proposed to combine fast EDM drilling methods with special materials and geometric properties of film cooling hole machining. A heat transfer module, a turbulent flow computational fluid dynamics module, a phase change module and a level set method are combined in this model. The complete process of generation, flow and solidification of molten materials is investigated by simulation with a single pulse discharging. The simulation results agree well with the experimental observation results. A thermal-mechanical coupling analysis of a molten material evolution process is carried out based on the temperature, velocity and pressure fields from the thermal-fluid model. Simulation results show that the molten material is generated at 1 µs after the starting of a discharge, and solidifies within 20 µs after the ending of the discharge. Under the influence of a high-speed flushing fluid, molten materials will not splash into a gap channel along the radial directions. Most of the molten material enters the gap channel along the workpiece surface with a velocity of over 25 m s −1 . The moving direction of the molten material is consistent with that of a flushing fluid. The thickness of a recast layer gradually increases from bottom to top in the fast EDM drilling.

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Prediction of crater morphology and its application for enhancing dimensional accuracy in micro-EDM

Yao,

Ye,

et al. 2024

J Intell Manuf

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Thermo-fluid multi-physics modeling and experimental verification of volumetric workpiece material removal by a discharge pulse in electric discharge machining process

Cited by 5 publications

References 70 publications

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

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

Study on the evolution process of recast layer for fast EDM drilling based on observation experiment and a novel thermal-fluid coupling model

Prediction of crater morphology and its application for enhancing dimensional accuracy in micro-EDM

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