Modeling of material removal rate and surface roughness generated during electro-discharge machining

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11 Citations (Scopus)

Abstract

This study reports on the numerical model development for the prediction of the material removal rate and surface roughness generated during electrical discharge machining (EDM). A simplified 2D numerical heat conduction equation along with additional assumptions, such as heat effect from previously generated crater on a subsequent crater and instantaneous evaporation of the workpiece, are considered. For the material removal rate, an axisymmetric rectangular domain was utilized, while for the surface roughness, a rectangular domain where every discharge resides at the end of previous crater was considered. Simulated results obtained by solving the heat equation based on a finite element scheme suggested that results are more realistic by considering instantaneous evaporation of the material from the workpiece and the effect of residual heat generated from each spark. Good agreement between our model and previously published data validated the newly proposed models and demonstrate that instantaneous evaporation, as well as residual heat, provide more realistic predictions of the EDM process.

Original languageEnglish
Article number47
JournalMachines
Volume7
Issue number2
DOIs
Publication statusPublished - Jun 1 2019

Keywords

  • Crater
  • EDM
  • Heat source
  • Material removal rate (MRR)
  • Surface roughness

ASJC Scopus subject areas

  • Computer Science (miscellaneous)
  • Control and Systems Engineering
  • Mechanical Engineering
  • Control and Optimization
  • Industrial and Manufacturing Engineering
  • Electrical and Electronic Engineering

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