Estimation of Aerosol Emission in Die Sinking EDM Process through Numerical Modelling

Abstract:

Emission of metallic particulate (aerosol) is an important hazard associated with the EDM process. These emissions can cause adverse health effects to the operators and has a direct impact on the environment. Therefore, concurrent investigations of the aerosol emission and machining aspects of the EDM process are essential for achieving hygienic and efficient machining. The aerosol emission from the process is directly related to the temperature at the process location. Hence, this paper first addresses a numerical model that quantifies the temperature distribution on the surface of a work piece and tool using ANSYS® 14.5. The model first calculates the temperature distribution in the workpiece material and then Material Removal Rate above the boiling temperature of workpiece and tool were estimated from the temperature profiles. Then, a model that quantifies the aerosol generated from EDM process is developed using energy balance and heat transfer equations. Validation of model has been done by comparing the results against the published experimental results obtained under the same process parameters. A good agreement was found between the experimental and numerical results. The model used in this paper can predict the level of emissions at different process locations in order to suggest suitable process conditions for green manufacturing.

• Periodical: Applied Mechanics and Materials (Volume 852)
• Pages: 290-296
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.852.290
• Online since: September 2016
• Authors: M. Nalla Mohamed*, J. Sylvya Rebecca
• Keywords: Aerosol Emission, Electro Discharge Machining (EDM), Numerical Modelling

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