Modeling and Simulation of Surface Topography Evolution in Electrical Discharge Machining (EDM)

2014 ◽  
Vol 1017 ◽  
pp. 764-769
Author(s):  
Tian Feng Zhou ◽  
Li Zheng Ma ◽  
Zhi Qiang Liang ◽  
Xi Bin Wang
Keyword(s):  
Surface Topography ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Pulse Discharge ◽  
Fem Simulation ◽  
Single Pulse ◽  
Machining Parameters ◽  
Workpiece Material ◽  
Material Erosion ◽  
Gauss Distribution

This paper aims to quantify the effects of the machining condition on the surface topography in electrical discharge machining (EDM), including pulse current, pulse duration and so on. Firstly, the heat source of a single electrical pulse is defined by Gauss distribution, and the thermal effects of machining parameters on the workpiece material erosion are simulated by Finite Element Method (FEM) package ANSYS. Then, the crater size of a single pulse is numerically simulated based on the thermal model of a single pulse discharge. Furthermore, the superposition of multiply craters created by continuous pulse discharges in a random distribution is calculated by MATLAB software program, so that the evolution of the surface topography can be obtained with the combination of FEM simulation and topology calculation. In this way, the surface roughness is quantitatively calculated from the specified EDM parameters.

Shifting Secondary Discharge as the Expulsion Mechanism in EDM

2008 ◽  
Author(s):  
Y. F. Luo ◽  
Jia Tao
Keyword(s):  
Energy Distribution ◽  
Driving Force ◽  
Electrical Discharge ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Pulse Discharge ◽  
Single Pulse ◽  
Complex Surface ◽  
Apparent Difference ◽  
Reversed Polarity

A new understanding of the expulsion mechanism in electrical discharge machining (EDM) is discussed in this investigation. The shifting secondary discharge inside a cathodic root is revealed as the major driving force for metal expulsion in EDM. A typical electrode couple of steel for cathode and copper for anode is used in all the experiments and discussions. Micro graphs of discharge craters are taken from the complex surface directly after a continual discharging process while either normal or reversed polarity is applied. The apparent difference in crater morphologies on anode and cathode indicates the unique expulsion mechanism, namely secondary discharges, which only take place inside the cathodic root. The compliance of secondary discharges with long-disputed phenomena, such as the discrepancy between energy distribution and metal removal, is demonstrated through the applications of the mechanism to the phenomena. The applied methods and results are more realistic since single pulse discharge among other process changes is prohibited. Such a more reliable understanding can correlate the complex metal removal mechanisms to better future process developments.

scholarly journals Experimental Study and Parameter Optimization of Hybrid Electrical Discharge Machining

2018 ◽  
Vol 7 (3.12) ◽  
pp. 1161
Author(s):  
Nishant Kumar Singh ◽  
Sandeep Agrawal ◽  
Rajvardhan . ◽  
Yashvir Singh
Keyword(s):  
Electrical Discharge ◽  
Oil And Gas ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Machining Parameters ◽  
Electrode Gap ◽  
Workpiece Material ◽  
Hybrid Machining Process ◽  
Pulse On Time

Hard materials cannot be machined effectively by the individual machining process. In order to machine workpiece made from hard and stiff materials effectively a concept of Hybrid machining process (HMP) is originated. The HMP is an integration of two or more machining process to get the advantage of each individual process. HMP is used to machine  This study focuses on evolving a novel process using both oil and gas as dielectrics to analyse the effect on tool wear rate (TWR) and material removal rate (MRR). The flow of compressed gas through eccentric-hole rotating tool improved the debris removal from inter-electrode gap, hence it improve the flushing competence of the machining process. In this experimental investigation, the workpiece material is Al-20% SiC metal matrix composite (MMC) and the electrode material is copper. The experiments were conducted following the Taguchi method of design experiments. The effect of various machining parameters on MRR and TWR has been studied. The optimization of process parameter has also been done. The results of TWR and MRR are analysed using S/N ratio, ANOVA and main effect plots. The experimental results, revels that discharge current, gap voltage and pulse on time significantly affected MRR, and TWR. The experimental inference reveal that provision of compressed air through eccentric hole rotary tool has a positive effect on machinability of electrical discharge machining (EDM) process.  

Mathematical Model for Wear Rate of Negative Graphite Electrode in Electrical Discharge Machining on Ti-5A1-2.5Sn

2012 ◽  
Vol 59 (2) ◽  
Author(s):  
Md. Ashikur Rahman Khan ◽  
M. M. Rahman ◽  
K. Kadirgama ◽  
A. R. Ismail
Keyword(s):  
Mathematical Model ◽  
Wear Rate ◽  
Tool Wear ◽  
Linear Model ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Parameters ◽  
Tool Wear Rate ◽  
Workpiece Material ◽  
Non Linear

There are several electrical and non-electrical factors having the significant effect on tool wear in electrical discharge machining (EDM). It is very difficult to select the parameters correctly. Likewise, the tool wear rate is changed dramatically with workpiece material and electrode material. Until now no attempt is appeared that yields the tool wear characteristics in EDM on Ti-5Al-2.5Sn retaining Graphite as electrode. Thus, in this study a mathematical model is developed to predict the tool wear rate which will provide the opportunity of proper selection of the EDM parameters and make the EDM cost effective. To model both the linear and non-linear equation is applied using the experimental data which are obtained performing the experimentation as design of experiment. The developed model has been verified through analysis of variance (ANOVA). The second-order non-linear model is found as appropriate as compared with a linear model. It is evidenced that the proposed model can effectively predict the tool wear rate (TWR) and adequately explains the variation in the machining parameters on TWR.

Effect of Discharge Condition on Cavitations Behavior by Single Pulse Discharge

2012 ◽  
Vol 523-524 ◽  
pp. 951-956
Author(s):  
Yoshiaki Akematsu ◽  
Kazuro Kageyama ◽  
Naotake Mohri ◽  
Hideaki Murayama
Keyword(s):  
Optical Fiber ◽  
Discharge Current ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Pulse Discharge ◽  
Optical Fiber Sensor ◽  
Single Pulse ◽  
Vibration Sensor ◽  
Work Piece ◽  
Discharge Condition

This paper describes some experimental results on a fundamental phenomenon of the single pulse discharge. In electrical discharge machining (EDM), processing accuracy was effected by behaviors of fused material. Pressure was important for removing fused material. So, it was needed to clarify that the mechanism of pressure occurrence by electrical discharge. In this study, it was investigated that effect of discharge condition on cavitations behavior by single pulse discharge. Gap region medium viscosity was changed by medium and temperature. Electrical discharge current was changed by applied voltage. The optical fiber vibration sensor is located on an aluminum work-piece (cathode) plate. Pressure was measured by optical fiber sensor during single pulse discharge. As the results, burst acoustic emission (AE) wave was occurred during single pulse discharge. The occurrence of several times burst AE wave was caused by cavitations behavior. The condition on which bubble does not collapse has become apparent. It was found that cavitations behavior was mainly depended on discharge current except for the condition on which bubble does not collapse.

Manufacture Probe with EDM Single Pulse Discharge Research

2011 ◽  
Vol 291-294 ◽  
pp. 3069-3072 ◽  
Author(s):  
Lan Chen
Keyword(s):  
Electrical Discharge ◽  
Tungsten Wire ◽  
Electrical Discharge Machining ◽  
Pulse Discharge ◽  
Single Pulse ◽  
Tungsten Electrode ◽  
Negative Pole ◽  
Tungsten Microelectrode ◽  
Measurement Devices ◽  
Fabrication Time

This paper presents a new method to fabricate tungsten microelectrode in a single pulse electrical discharge. The electrode material, diameter and polarity affect the shape of probe. The 80μm diameter tungsten wire between 500 and 600μF capacitance can be fabricated in 1μm tungsten electrode probe tip. The experiment use different material such as W, Cu and Mo. Finally, in the condition of “negative pole machining”, only tungsten can be used to make probe. It can greatly shorten the microelectrode fabrication time and effectively improve the reliability of the microelectrode and can fabricate a nanometer level tip in general electrical discharge machining (EDM) machine tool not add any other apparatus. The fabricated microelectrode can be used as a probe for scanner and measurement devices.

Gap Phenomena of Ultrasonic Vibration Assisted Electrical Discharge Machining in Gas

2008 ◽  
Vol 375-376 ◽  
pp. 500-504
Author(s):  
Qin He Zhang ◽  
Jian Hua Zhang ◽  
Shu Peng Su ◽  
Qing Gao
Keyword(s):  
Ultrasonic Vibration ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Pulse Discharge ◽  
Single Pulse ◽  
Environment Pollution ◽  
Dielectric Fluids ◽  
Simple Tool ◽  
Spark Plasma

Ultrasonic vibration aided electrical discharge machining (UEDM) in gas is a new machining technology developed in recent years. This technology uses air or oxygen as dielectric and ultrasonic vibration is applied to the workpiece during machining. UEDM in gas can avoid environment pollution, the most serious disadvantage of conventional EDM in kerosene-based oil or other dielectric fluids, and it is environmental-friendly. The technology also has virtues of wide applications, high machining efficiency, and simple tool electrodes and so on. In this paper, the formation and transformation of the spark plasma and the mechanism of material removal during a single pulse discharge are introduced.

Mathematical Modeling of Machining Parameters in Electrical Discharge Machining with Cu-B4C Composite Electrode

2012 ◽  
Vol 488-489 ◽  
pp. 871-875
Author(s):  
V. Anandakrishnan ◽  
V. Senthilkumar
Keyword(s):  
Mathematical Models ◽  
Current Pulse ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Selection Of

Copper based metal matrix composite reinforced with Boron Carbide is a newly developed Electrical Discharge Machining (EDM) electrode showing better performance than the conventional copper based electrode. Right selection of machining parameters such as current, pulse on time and pulse off time is one of the most important aspects in EDM. In this paper an attempt has been made to develop mathematical models for relating the Material Removal Rate (MRR), Tool Removal Rate (TRR) and Surface roughness (Ra) to machining parameters (current, pulse-on time and pulse-off time). Furthermore, a study was carried out to analyze thSubscript texte effects of machining parameters on various performance parameters such as, MRR, TRR and Ra. The results of Analysis of Variance (ANOVA) indicate that the proposed mathematical models, can adequately describe the performance within the limits of the factors being studied. Response surface modeling is used to develop surface and contour graphs to analyze the effects of EDM input parameters on outer parameters.

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