In this paper, the 2D surface model of single and multi-spark impacts on electrical discharge machining (EDM), with precise consideration of spark propagation, has been developed and simulated. Theoretical correlation between the input parameters, viz. discharge voltage (V): 30–110 V, discharge current (I): 5–75 A and spark on time (Ton): 10–200 µs, were preliminarily established, using the governing equations. The scope of the paper was to model the spark impact phenomenon, so as to determine the most influential factors which can be controlled to produce the required surface finish, for specific applications. Fine/finish machining is achievable at low discharge current, moderate discharge voltage and medium pulse on time, whereas coarse machining requires reverse conditions, preferably. Multi-spark analysis imparts insight into the possibilities in prediction and evaluation of material removal rate (MRR) and surface roughness (Ra) through further design considerations.
EDM Modelling and simulation Single and Multi-spark analyses
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This work was carried out by the aid of research grant sanctioned from the Science and Engineering Research Board (SERB), DST, Govt. of India (Project Ref. No. ECR/2016/001929). Also, the authors are grateful to Mr. Anjan Karmakar for his significant contribution towards this initiative.