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Thermal modeling of single discharge in prospect of tool wear compensation in μEDM

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Abstract

Due to the non-isoenergetic nature of discharge pulses in resistance-capacitance (RC) based micro electrical discharge machining (μEDM), the volume of produced micro-crater by each pulse varies significantly. This fact has driven the researchers in this work to propose an electrothermal principle–based analytical model to approximate dimensional accuracies of such micro-craters. A finite element (FE) simulation considering Gaussian heat flux distribution of single discharge μEDM has been performed at significant input parameters such as discharge energy, capacitance, and open-circuit voltage and compared with analytical simulation results. Upon validation of these simulated results with experimental results, nominal dimensional inaccuracies of 2–11% for a wide range of input parameters have been noticed. This effectively predicted crater dimension from the workpiece can be incorporated in the proposed thermal modeling–based real-time tool wear monitoring and compensation system through a unique strategy, which is discussed at the end.

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Abbreviations

μEDM:

Micro electrical discharge machining

CFD:

Computational fluid dynamics

DAQ:

Data acquisition card

EDS:

Energy dispersive spectroscopy

FE:

Finite element

FD:

Finite difference

MRR:

Material removal rate

PD:

Pulse discrimination

SR:

Surface roughness

SEM:

Scanning electron microscopy

TWR:

Tool wear rate

V MR :

Actual volume removal

V target :

Target volume

VRD:

Volume removal per discharge

c p :

Average specific heat (Jkg−1K−1.)

C :

Combination of fraction energy and a fraction of molten area (Dimensionless)

erfc :

Complementary error function (Dimensionless)

E P :

Energy of each pulse (μJ)

E :

Complete elliptic integrals of the second kind (Dimensionless)

h c :

Convective heat transfer coefficient (Wm−2K)

I a :

Average current (A)

J 0 :

Bessel function of the first kind of zero-order (Dimensionless)

J 1 :

Bessel function of the first kind of first-order (Dimensionless)

K t :

Thermal conductivity of the material (Wm−1K−1)

K :

Complete elliptic integrals of the first kind (Dimensionless)

L m :

Latent heat of melting (kJ/kg)

L V :

Latent heat of vaporization (kJ/kg)

N p :

Number of actual contributing pulses (Dimensionless)

q :

Heat flux (Wm−2)

R a :

Heat flux radius at anode (μm)

r :

Radial coordinates (μm)

R :

Heat flux radius (μm)

t :

Time in seconds (s)

T :

Temperature (K)

T s :

Solidus temperature (K)

T l :

Liquids temperature (K)

T 0 :

Ambient temperature (K)

t on :

Pulse on time (μs)

u :

Dimensionless radius (Dimensionless)

V a :

Average voltage (V)

V 0 :

Open circuit voltage (V)

α :

Thermal diffusivity of material (m2s−1)

λ :

Dummy variables (Dimensionless)

ρ :

Density of material (kgm−3)

θ :

Ratio of anode erosion rate (Dimensionless)

τ :

Dimensionless time (Dimensionless)

w :

Dimensionless depth (Dimensionless)

z :

Depth or axial coordinates (μm)

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Funding

The authors received financial support from the Department of Science and Technology (DST) Govt. of India (Grant No. ECR/DST/2017/000918)

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  1. Department of Mechanical Engineering, Indian Institute of Technology Ropar, Rupnagar, Punjab, 140001, India

    Rahul Nadda & Chandrakant Kumar Nirala

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  1. Rahul Nadda
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Correspondence to Chandrakant Kumar Nirala.

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Nadda, R., Nirala, C.K. Thermal modeling of single discharge in prospect of tool wear compensation in μEDM. Int J Adv Manuf Technol 107, 4573–4595 (2020). https://doi.org/10.1007/s00170-020-05238-5

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