A finite element based model for electrochemical discharge machining in discharge regime

Electrochemical discharge machining (ECDM) is a promising hybrid process for high-performance machining of non-conductive glass. ECDM drilling has been found to have different characteristics and material removal mechanisms in discharge regime (less than 300 μm in depth) and hydrodynamic regime (mor...

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Bibliographic Details
Published in:International journal of advanced manufacturing technology 2011-06, Vol.54 (9-12), p.987-995
Main Authors: Wei, Chenjun, Xu, Kaizhou, Ni, Jun, Brzezinski, Adam John, Hu, Dejin
Format: Article
Language:English
Subjects:
CAE) and Design
Computer simulation
Computer-Aided Engineering (CAD
Discharge
Drilling
Engineering
Finite element method
Industrial and Production Engineering
Machining
Mathematical analysis
Mechanical Engineering
Media Management
Original Article
Predictions
Workpieces
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Summary:Electrochemical discharge machining (ECDM) is a promising hybrid process for high-performance machining of non-conductive glass. ECDM drilling has been found to have different characteristics and material removal mechanisms in discharge regime (less than 300 μm in depth) and hydrodynamic regime (more than 300 μm in depth); however, these regimes are never separately modeled in existing ECDM models, which leads to large prediction error, especially at low applied voltages and high machining depths. Until now, no model is particularly designed for discharge regime, where most material is removed. In this paper, a finite element based model for ECDM drilling in discharge regime is presented. Material removal subjected to a single spark was simulated using finite element method. The drilling depth evolution in discharge regime was predicted. The model predictions were compared with experimental results for validation. The fraction of power transferred to workpiece was found to be about 29% in discharge regime.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-010-3000-0