Advertisement

Numerical Modelling and Simulation of Single and Multi-spark Impacts in Electrical Discharge Machining

  • Jibin T. Philip
  • Basil KuriachenEmail author
  • Jose Mathew
Conference paper
Part of the Lecture Notes on Multidisciplinary Industrial Engineering book series (LNMUINEN)

Abstract

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.

Keywords

EDM Modelling and simulation Single and Multi-spark analyses 

Notes

Acknowledgements

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.

References

  1. 1.
    Singh, A., Ghosh, A.: A thermo-electric model of material removal during electric discharge machining. Int. J. Mach. Tools Manuf. 39(4), 669–682 (1999).  https://doi.org/10.1016/S0890-6955(98)00047-9CrossRefGoogle Scholar
  2. 2.
    DiBitonto, D.D., Eubank P.T., Patel, M.R., Barrufet, M.A.: Theoretical models of the electrical discharge machining process. I. A simple cathode erosion model. J. Appl. Phys. 66(9), 4095–4103 (1989).  https://doi.org/10.1063/1.343994CrossRefGoogle Scholar
  3. 3.
    Patel, M.R., Barrufet, M.A., Eubank, P.T., DiBitonto, D.D.: Theoretical models of the electrical discharge machining process. II. The anode erosion model. J. Appl. Phys. 66(9), 4104–4111 (1989).  https://doi.org/10.1063/1.343995CrossRefGoogle Scholar
  4. 4.
    Jilani, S.T., Pandey, P.C.: Analysis and modelling of EDM parameters. Precis. Eng. 4(4), 215–221 (1982).  https://doi.org/10.1016/0141-6359(82)90011-3CrossRefGoogle Scholar
  5. 5.
    Jilani, S.T., Pandey, P.C.: An analysis of surface erosion in electrical discharge machining. Wear 84(3), 275–284 (1983).  https://doi.org/10.1016/0043-1648(83)90269-7CrossRefGoogle Scholar
  6. 6.
    Van Dijck, F.S., Dutre, W.L.: Heat conduction model for the calculation of the volume of molten metal in electric discharges. J. Phys. D Appl. Phys. 7(6), 899 (1974).  https://doi.org/10.1088/0022-3727/7/6/316CrossRefGoogle Scholar
  7. 7.
    Das, S., Klotz, M., Klocke, F.: EDM simulation: finite element-based calculation of deformation, microstructure and residual stresses. J. Mater. Process. Technol. 142(2), 434–451 (2003).  https://doi.org/10.1016/S0924-0136(03)00624-1CrossRefGoogle Scholar
  8. 8.
    Joshi, S.N., Pande, S.S.: Development of an intelligent process model for EDM. Int. J. Adv. Manuf. Technol. 45(3–4), 300 (2009).  https://doi.org/10.1007/s00170-009-1972-4CrossRefGoogle Scholar
  9. 9.
    Beck, J.V.: Transient temperatures in a semi-infinite cylinder heated by a disk heat source. Int. J. Heat Mass Transf. 24(10), 1631–1640 (1981).  https://doi.org/10.1016/0017-9310(81)90071-5CrossRefzbMATHGoogle Scholar
  10. 10.
    Beck, J.V.: Large time solutions for temperatures in a semi-infinite body with a disk heat source. Int. J. Heat Mass Transf. 24(1), 155–164 (1981).  https://doi.org/10.1016/0017-9310(81)90104-6MathSciNetCrossRefGoogle Scholar
  11. 11.
    Snoyes, R., Van Dijck, F.: Investigations of EDM operations by means of thermo mathematical models. Ann. CIRP 20(1), 35 (1971)Google Scholar
  12. 12.
    Snoeys, R.: Plasma channel diameter growth affects stock removal in EDM. Ann. CIRP 21, 39–40 (1972)Google Scholar

Copyright information

© Springer Nature Singapore Pte Ltd. 2020

Authors and Affiliations

  1. 1.Department of Mechanical EngineeringNational Institute of Technology MizoramAizawlIndia
  2. 2.Department of Mechanical EngineeringNational Institute of Technology CalicutCalicutIndia

Personalised recommendations