Thermo-physical modeling of die-sinking EDM process

Joshi, Shrikrishna N.; Pande, S.S.

doi:10.1016/j.jmapro.2010.02.001

Cited by 220 publications

(130 citation statements)

References 29 publications

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“…Since the precise position of each spark is random, the effect of single discharge is useful in developing an inside into the temperature distribution at electrodes during each discharge. Consequently, the thermal effects of successive sparks are neglected and the crater is individually identified to simplify the simulation process [7,16]. 4.…”

Section: Mathematical Fundamentsmentioning

confidence: 99%

Mathematical and numerical modeling of the effect of input-parameters on the flushing efficiency of plasma channel in EDM process

Shabgard

Ahmadi

Seyedzavvar

et al. 2013

International Journal of Machine Tools and Manufacture

136

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a b s t r a c tIn the present study, the temperature distribution on the surface of workpiece and tool during a single discharge in the electrical discharge machining process has been simulated using ABAQUS code finite element software. The temperature dependency of material properties and the expanding of plasma channel radius with time have been employed in the simulation stage. The profile of temperature distribution has been utilized to calculate the dimensions of discharge crater. Based on the results of FEM and the experimental observations, a numerical analysis has been developed assessing the contribution of input-parameters on the efficiency of plasma channel in removing the molten material from molten puddles on the surfaces of workpiece and tool at the end of each discharge. The results show that the increase in the pulse current and pulse on-time have converse effects on the plasma flushing efficiency, as it increases by the prior one and decreases by the latter one. Later, the introduced formulas for plasma flushing efficiency based on regression model were utilized to predict the cardinal parameter of recast layer thickness on the electrodes which demands expensive empirical tests to be obtained.

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Section: Mathematical Fundamentsmentioning

confidence: 99%

Mathematical and numerical modeling of the effect of input-parameters on the flushing efficiency of plasma channel in EDM process

Shabgard

Ahmadi

Seyedzavvar

et al. 2013

International Journal of Machine Tools and Manufacture

136

View full text Add to dashboard Cite

show abstract

“…1a), which can be used to model and simulate the EDM process. Assuming the nature of these sparks to be the same, we can model one of them and extend it to all the sparks that happen during the process [14,16]. A small cylindrical portion of the workpiece around the spark is chosen for analysis, which is shown in Fig.…”

Section: Edm Processmentioning

confidence: 99%

“…Comparative analyses on the MRR ratio of the predicted result to experimental data for discharge energy range from 0.33 to 952 mJ showed that DiBitonto's model yielded the closest proximity of 1.2-46.1 MRR ratio. In 2010, Joshi et al [16] presented an investigation on MRR simulation and shape of the crater cavity considering more realistic assumptions. They carried out their research in two phases: in the first section, they compared their results with one reported by Dibitonto et al and reported that their model predicts results closer to experimental data; in the second phase, they investigated MRR and crater shape on AISI P20, considering the PFE as 100 % and F c as 18 %.…”

Section: Introductionmentioning

confidence: 99%

“…Most of the reported theoretical models based on thermal analysis have limited applicability as they are based on assumptions like approximation of heat source as a point or disk-shaped (uniform) [2][3][4][5][6][7][8], constant heat flux radius [2][3][4][5][6][7][8]10], constant thermal properties of work/tool materials [2-8, 10, 13], the lack of applying PFE [2][3][4][5][6][7][8][9][10][11][12][13][14]16], and calculating the exact value for energy distribution factor [2][3][4][5][6][7][10][11][12][13][14][15][16][17]. A need to eliminate these simplifying assumptions to make the model more realistic thus exists in order to accurately predict the shape and size of EDM-induced craters.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Experimental and finite element analysis of EDM process and investigation of material removal rate by response surface methodology

Kalajahi

Ahmadi

Oliaei

2013

Int J Adv Manuf Technol

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In this study, thermal modeling and finite element simulation of electrical discharge machining (EDM) has been done, taking into account several important aspects such as temperature-dependent material properties, shape and size of the heated zone (Gaussian heat distribution), energy distribution factor, plasma flushing efficiency, and phase change to predict thermal behavior and material removal mechanism in EDM process. Temperature distribution on the cathode has been calculated using ANSYS finite element code, and the effect of EDM parameters on heat distribution along the radius and depth of the workpiece has been obtained. Temperature profiles have been used to calculate theoretical material removal rate (MRR) from the cathode. Theoretically calculated MRRs are compared with the experimental results, making it possible to precisely determine the portion of energy that enters the cathode for AISI H13 tool steel. Also in this paper, the effect of EDM parameters on MRR has been investigated by using the technique of design of experiments and response surface methodology. Finally, a quadratic polynomial regression model has been proposed for MRR, and the accuracy of this model has been checked by means of analysis of residuals.

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“…Results showed that with reduction in relative stability coefficient of the discharge duty ratio, the recast layer thickness and induced stress were increased. Joshi and Pande (2010) performed experiments on die-sinking EDM process to study the MRR and crater shapes produced during machining. Puertas and Luis (2012) analyzed the influence of intensity of current, pulse duration, duty cycle, open circuit voltage and dielectric flushing pressure on the quality of EDM machining of B4C and WC-Co ceramics.…”

Section: Introductionmentioning

confidence: 99%

Performance optimization in electro- discharge machining using a suitable multiresponse optimization technique

Nayak¹,

Rana²,

Parida³

2017

10.5267/j.dsl

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In the present research work, four different multi response optimization techniques, viz. multiple response signal-to-noise (MRSN) ratio, weighted signal-to-noise (WSN) ratio, Grey relational analysis (GRA) and VIKOR (VlseKriterijumska Optimizacija I Kompromisno Resenje in Serbian) methods have been used to optimize the electro-discharge machining (EDM) performance characteristics such as material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR) simultaneously. Experiments have been planned on a D2 steel specimen based on L9 orthogonal array. Experimental results are analyzed using the standard procedure. The optimum level combinations of input process parameters such as voltage, current, pulse-on-time and pulse-off-time, and percentage contributions of each process parameter using ANOVA technique have been determined. Different correlations have been developed between the various input process parameters and output performance characteristics. Finally, the optimum performances of these four methods are compared and the results show that WSN ratio method is the best multiresponse optimization technique for this process. From the analysis, it is also found that the current has the maximum effect on the overall performance of EDM operation as compared to other process parameters.Growing Science Ltd. All rights reserved. 7

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Thermo-physical modeling of die-sinking EDM process

Cited by 220 publications

References 29 publications

Mathematical and numerical modeling of the effect of input-parameters on the flushing efficiency of plasma channel in EDM process

Mathematical and numerical modeling of the effect of input-parameters on the flushing efficiency of plasma channel in EDM process

Experimental and finite element analysis of EDM process and investigation of material removal rate by response surface methodology

Performance optimization in electro- discharge machining using a suitable multiresponse optimization technique

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