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Multi-spark simulation of the electrochemical discharge machining (ECDM) process

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Abstract

Electrochemical discharge machining (ECDM) has been studied numerically by several researchers using single spark simulation during finite element modeling (FEM) for analyzing the material removal rate (MRR). However, the process includes the stochastic nature of the spark striking that leads to complexities. Because of this randomness, FEM based multi-spark simulation has not attempted till date. This article attempts to develop an improved model based on a randomly oriented multi-sparks for estimating the MRR. Gradually growing spark behavior and Gaussian heat input are utilized for acquiring the temperature distributions within the work-material. The temperature distributions are further processed to evaluate the MRR with consideration of craters overlapping formed during the multi-spark occurrence. The predicted results exhibit a fair agreement with the experimental results. The simulation-based parametric studies are performed on MRR using applied voltage, electrolyte concentration, and energy transference since it influences the total heat input energy given by the sparks.

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Acknowledgment

The authors acknowledge the support and assistances given by the Punjab Engineering College, Chandigarh, India.

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Authors and Affiliations

  1. Production and Industrial Engineering Department, Punjab Engineering College, Chandigarh, 160012, India

    Viveksheel Rajput, Mudimallana Goud & Narendra Mohan Suri

Authors
  1. Viveksheel Rajput
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  2. Mudimallana Goud
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  3. Narendra Mohan Suri
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Corresponding author

Correspondence to Viveksheel Rajput.

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A Viveksheel Rajput is pursuing a Ph.D. degree in Production and Industrial Engineering Department from Punjab Engineering College (PEC), Chandigarh, India. He obtained his bachelor’s degree from Punjab Technical University, Punjab, Indian (2010), and completed his Master’s degree from PEC (2013). His area of research is non-conventional machining processes, Finite element modeling, composite materials. He has published more than 15 papers in reputed journals.

Mudimallana Goud is an Associate professor in the Production and Industrial Engineering Department, Punjab Engineering College, Chandigarh, India. He is the former Head of the department also. He obtained his Ph.D. degree from at Indian Institute of Technology Roorkee, Roorkee, India (2016). He has published more than 40 research papers in reputed journals. His prime area of research is Non-conventional machining and Advanced Machining Processes.

Narendra Mohan Suri is a Professor in the Production and Industrial Engineering Department, Punjab Engineering College, Chandigarh, India. Formerly, he is Head of Total Quality Management (TQM). He obtained his Ph.D. degree from at Indian Institute of Technology Delhi, Delhi, India (2005). He has published more than 80 research papers in reputed journals. His prime area of research is Welding Engineering, Casting, Composite Fabrication Al/Mg alloys casting.

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Rajput, V., Goud, M. & Suri, N.M. Multi-spark simulation of the electrochemical discharge machining (ECDM) process. J Mech Sci Technol 35, 5127–5135 (2021). https://doi.org/10.1007/s12206-021-1029-7

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  • DOI: https://doi.org/10.1007/s12206-021-1029-7

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