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Anode Power Deposition in Dry EDM

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Abstract

Dry electrical discharge machining (DEDM) has been developed as an environmentally friendlier alternative to the traditional EDM in oil-based dielectric. Proper understanding of the physics of the DEDM discharges is necessary in order to improve this new manufacturing technology, since its workpiece material removal and tool electrode wear mechanisms are governed by plasma-material interactions. The present work proposes the application of theoretical models, numerical simulations, and advanced diagnostics from the field of plasma physics as effective tools to estimate the electric discharge power deposition onto the anode workpiece in DEDM. Collisional-radiative models are used here to calculate several plasma properties, from which the anode power deposition can be estimated. In addition, electrical circuit simulations, which use a modified Cassie-Mayr model, calculate the fraction of the total electric discharge power that is consumed by thermal conduction into the anode electrode material. The methods proposed in the present work provide fundamental information for further workpiece material erosion modelling and simulation under different DEDM processing conditions.

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Acknowledgement

We would like to thank Dr. Raoul Roth for his great collaboration.

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Authors and Affiliations

  1. Institute of Machine Tools and Manufacturing (IWF), ETH Zurich, Leonhardstrasse 21, 8092, Zurich, Switzerland

    Felipe T. B. Macedo, Moritz Wiessner, Caroline P. Martendal, Friedrich Kuster & Konrad Wegener

  2. Lutry, Switzerland

    Christoph Hollenstein

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  1. Felipe T. B. Macedo
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  2. Moritz Wiessner
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  3. Christoph Hollenstein
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  4. Caroline P. Martendal
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Correspondence to Felipe T. B. Macedo.

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Macedo, F.T.B., Wiessner, M., Hollenstein, C. et al. Anode Power Deposition in Dry EDM. Int. J. of Precis. Eng. and Manuf.-Green Tech. 6, 197–210 (2019). https://doi.org/10.1007/s40684-019-00051-2

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