Finite Element Analysis of Material Removal Rate in Electrical Discharge Machining Process and its Comparison with Experiments

Abstract:

The non-convectional machining processes are those using thermal source of energy for the material removal. Among them Electrical discharge machining (EDM) or spark erosion machining is most important one. The important process parameters in this technique are discharge pulse on time, discharge pulse off time current and gap voltage. The values of these parameters significantly affect such machining outputs as material removal rate. In this paper, an axisymmetric thermo-physical finite element model for the simulation of single sparks machining during electrical discharge machining (EDM) process is exhibited. The model has been solved using ANSYS 11.0 software. A transient thermal analysis assuming a Gaussian distribution heat source with temperature-dependent material properties has been used to investigate the temperature distribution. Material removal rate was calculated for multi-discharge machining by taking into considerations the number of pulses. Comparison, analyzation of the theoretical result and experimental result by considering the same process parameters has been done, and the result is highly agreed between the experimental and theoretical value so the model is validated.

• Periodical: Advanced Materials Research (Volumes 984-985)
• Pages: 48-55
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.984-985.48
• Online since: July 2014
• Authors: Sibakanta Sahu*, Swarup Kumar Nayak, Saipad Sahu, Pallavi Chaudhury
• Keywords: Electrical Discharge Machining (EDM), Finite Element Method (FEM), Modeling, Multi Discharge, Simulation

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