A contribution in EDM simulation field

Tlili, Adnene; Ghanem, Farhat; Salah, Nizar Ben

doi:10.1007/s00170-015-6880-1

Cited by 46 publications

(13 citation statements)

References 31 publications

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“…Both constant and expanding plasma heating radii have been used by different researchers [18][19][20]24,38,39]. In this research, the following semi-empirical relation for "equivalent heat input radius," proposed by Ikai and Hashiguchi [40], was used: R p = 2.04 I 0.43 t 0.44 (13) where I is the discharge current in amperes, t is discharge time, and R p is the plasma radius in micrometers.…”

Section: Plasma Radiusmentioning

confidence: 99%

“…where V c is crater volume, t on is pulse-on time and t off is the pulse-off time. A program using MATLAB 2018 (MathWorks Inc., Natick, MA, USA), was developed to calculate MRR based on Equations (18) and (19).…”

Section: Effects Of Process Parameters On Materials Removal Ratementioning

confidence: 99%

“…Machines 2019, 7, x www.mdpi.com/journal/machines = + (19) where Vc is crater volume, ton is pulse-on time and toff is the pulse-off time. A program using MATLAB 2018 (MathWorks Inc., Natick, MA, USA), was developed to calculate MRR based on Equations (18) and (19 The dependency of MRR on the pulse duration for different currents is shown in Figure 3. For all the discharge currents, MRR was found to increase with pulse duration to a maximum value and then decrease again.…”

Section: Effects Of Process Parameters On Materials Removal Ratementioning

confidence: 99%

“…By using inverse identification, they have estimated the material removal rate and surface roughness within a 6% error margin. Tlili et al [19] developed a numerical model based on a finite difference scheme where they assumed instantaneous material removal during discharge. Marafona and Chousal [20] proposed a thermo-electrical model based on finite element method where they considered the Joule effect as a main heat generation mechanism in EDM.…”

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confidence: 99%

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Modeling of Material Removal Rate and Surface Roughness Generated during Electro-Discharge Machining

et al. 2019

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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. Machines 2019, 7, 47 2 of 17 model where the problem of heat conduction for both infinite and semi-infinite bodies with a constant heat source was solved. DiBitonto et al. [7] developed a point heat source cathode erosion model. Since spherical symmetry was considered in their model, the heat transfer equation in spherical coordinates was implemented. In their model, the constant cathode energy fraction of 0.183 was assumed. In their subsequent study [8], they developed an anode erosion model, by assuming a disk heat source. Beck et al.[9] developed a model to find the temperature distribution of a semi-infinite cylinder with a constant heat source and an insulated boundary. Since this model was not developed particularly for the EDM process, the heat fraction to the workpiece is not considered.Process performances of EDM have been investigated by many researchers. D'Urso et al.[10] defined a process index based on process parameters and material properties to analyze the process and geometric indexes of micro-EDM process. D'Urso and Ravasio [11], based on a material-technology index (MTI), studied the process performance of micro-EDM. Tsai and Masuzawa [12] analyzed the electrode wear of different electrode materials in a micro-EDM process. Based on experimental results, a new wear resistance index based on modified boiling and melting points for the evaluation of erosion performance was proposed. Marafona and Araujo [13] proposed an additive model to investigate the influence of hardness on the material removal rate and surface roughness. Alshemary et al. [14] studied effects of different process parameters on fabricating cylindrical holes by wire-EDM. Mandal et al. [15] investigated the surface integrity of wire-EDM. They reported that both grinding and etching-grinding techniques removed the recast layer, and hence improved the surface integrity. Prakash et al. [16] proposed altering the EDM process for coating TiO 2 -T...

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Section: Plasma Radiusmentioning

confidence: 99%

Section: Effects Of Process Parameters On Materials Removal Ratementioning

confidence: 99%

Section: Effects Of Process Parameters On Materials Removal Ratementioning

confidence: 99%

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confidence: 99%

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Modeling of Material Removal Rate and Surface Roughness Generated during Electro-Discharge Machining

et al. 2019

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“…However, in the case of traditional EDM, hazardous gases, aerosols, and other byproducts are created, which have a detrimental impact on the environment and endanger the health of people in the workplace. There has been a lot of study done on numerical modelling and optimization of process parameters of the EDM manufacturing process [5]. They are mostly concerned with dry, wet, and powder-mixed EDM, but a few research have been conducted in the field of near-dry EDM.…”

Section: Introductionmentioning

confidence: 99%

Finite Element based Numerical Modelling of Near-Dry EDM with Glycerin-Air Dielectric Mixture

Namboodiri

Pazhamannil

Govindan

2022

IOP Conf. Ser.: Mater. Sci. Eng.

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Electrical discharge machining (EDM) is an advanced, non-traditional machining process that is widely employed in sectors such as manufacturing, automotive, aerospace, and medicine. Near-dry EDM is a prospective technology that offers advantages over dry and wet EDM in terms of material removal rate (MRR), tool wear rate (TWR), and surface integrity. A 2D model of the axi-symmetric workpiece based on the Gaussian distribution of the heat flux is used to simulate the single spark in near-dry EDM. The MRR of near-dry EDM is determined at various glycerin flow rates in the glycerin-air combination. The simulation is then performed on the SS304 workpiece with different glycerin flow rates. The results are compared to EDM simulations using N2 and O2 as the dielectric medium. The average MRR of near-dry EDM with an 8 ml/min glycerin flow rate is determined to be 204% higher than that of N2 and 117% higher than that of O2 gas dielectric. When the volumetric ratio of glycerin in the glycerin-air combination increases, the MRR was also found to be increasing. The maximal MRR of near-dry EDM was found to be 129.30703 mm3/min with an 8 ml/min glycerin flow rate and a 0.18 volumetric ratio and a maximal MRR of 144.3407 mm3/min was found with a 15 ml/min glycerin flow rate and a 0.35 volumetric ratio.

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