Electrical discharge machining modeling by coupling thermal analysis with deformed geometry feature

Electrical discharge machining (EDM) is a non-conventional machining process, widely used in the modern industry. The stochastic nature of the process and the complexity of the occurring phenomena are the major difficulties in modeling of EDM. The current study presents a novel approach on EDM model...

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Bibliographic Details
Published in:International journal of advanced manufacturing technology 2019-08, Vol.103 (9-12), p.4481-4493
Main Authors: Papazoglou, E. L., Markopoulos, A. P., Papaefthymiou, S., Manolakos, D. E.
Format: Article
Language:English
Subjects:
CAE) and Design
Computer simulation
Computer-Aided Engineering (CAD
Coupling
Deformation
Electric discharge machining
Engineering
Erosion mechanisms
Erosion rates
Geometry
Heat affected zone
Industrial and Production Engineering
Machine shops
Mechanical Engineering
Media Management
Modelling
Original Article
Thermal analysis
Thickness
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Summary:Electrical discharge machining (EDM) is a non-conventional machining process, widely used in the modern industry. The stochastic nature of the process and the complexity of the occurring phenomena are the major difficulties in modeling of EDM. The current study presents a novel approach on EDM modeling, by coupling a heat transfer thermal analysis with deformed geometry feature. The deformation rate was calculated proportional to the spark erosion, leading to more accurate and realistic results. To validate the simulations results, a series of experiments were carried out on AISI O1 work-steel, with changing machining parameters the pulse current and the pulse-on time. The model validation criteria were the geometry of the formed craters, the average white layer thickness, and the heat-affected zone thickness. The simulation results were in agreement with experimental ones, suggesting that deformed geometry feature is important and suitable in modeling of EDM.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-019-03850-8