A simulation-based approach for modelling of fraction of energy transfer to workpiece in electrical discharge machining

Sanghani, C. R.; Acharya, G.D.; Kothari, Kartik D.

doi:10.1504/ijmr.2020.108231

Cited by 4 publications

(5 citation statements)

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“…Electric discharge deformation is an electro-thermal process that occurs by discrete and repetitive electrical sparks between two electrodes separated by a small distance. The high temperature plasma channel causes local melting and vaporization and erodes tiny amount of materials from the work surface [16]. To conduct a thermo-physical analysis of a single spark operation between connectors during current discharge a Gaussian-distributed heat flux [17] with sufficient boundary condition is utilized in FE.…”

Section: Electric Discharge and Modeling Proceduresmentioning

confidence: 99%

“…The effective amount of heat rate entering the workpiece converted to thermal energy and absorbed by the workpiece. Relation (1) presents the heat flux as a function of radius via Gaussian distribution during electric discharging [16]: Due to high-temperature gradients during discharging, several thermo-physical properties such as specific heat, density, and thermal conductivity shall be considered. Since the electrodischarge analysis process is an intricate and complicated, the following assumptions are considered to simplify the process:…”

Section: A Heat Fluxmentioning

confidence: 99%

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Effect of Faulty Solenoid Starter on the DC Series Motor Performance in Railway Industry

Yousefnejad,

Amiri,

Sarparast

et al. 2023

IEEE Access

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Cranking railway engines in high currents could lead to a series of undesirable effects on the starter motor such as melting copper contacts and disk inside the solenoid. This paper investigates the impact of a defective solenoid on the performance of a DC series motor starter. First, the effect of the starting system on the solenoid parts (i.e., the melting phenomenon in copper contacts and disk inside the solenoid) is described via Finite Element (FE). Next, the circuit model of the DC series motor with the solenoid starter is established to obtain the motor performance. Results reveal that subjecting the contactor disk to a current of 1250 A for 30 ms would melt the disk and cause surface defects. The faulty/melted disk subsequently raises the circuit resistance to 2.9 m ohms. The presented solution can detect the faults effect within 0.05 s time frame. Simulation results are supported via a series of experimental measurements and detailed theoretical discussion.

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Section: Electric Discharge and Modeling Proceduresmentioning

confidence: 99%

Section: A Heat Fluxmentioning

confidence: 99%

Effect of Faulty Solenoid Starter on the DC Series Motor Performance in Railway Industry

Yousefnejad,

Amiri,

Sarparast

et al. 2023

IEEE Access

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“…Electrical Discharge Machining (EDM) is an electrothermal and nonconventional machining process in which rapid and repetitive sparks are generated between the workpiece and tool, which are kept apart at a small gap of 0.001–0.5 mm and are submerged or flooded by dielectric fluid, by initiation of sparks controlled erosion of conductive material takes place 1 . Each spark produces enough heat to melt and evaporate material.…”

Section: Introductionmentioning

confidence: 99%

Surface roughness prediction of AISI D2 tool steel during powder mixed EDM using supervised machine learning

Kaigude,

Khedkar,

Jatti

et al. 2024

Sci Rep

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Surface integrity is one of the key elements used to judge the quality of machined surfaces, and surface roughness is one such quality parameter that determines the pass level of the machined product. In the present study, AISI D2 steel was machined with electric discharge at different process parameters using Jatropha and EDM oil. Titanium dioxide (TiO2) nanopowder was added to the dielectric to improve surface integrity. Experiments were performed using the one variable at a time (OVAT) approach for EDM oil and Jatropha oil as dielectric media. From the experimental results, it was observed that response trends of surface roughness (SR) using Jatropha oil are similar to those of commercially available EDM oil, which proves that Jatropha oil is a technically and operationally feasible dielectric and can be efficiently replaced as dielectric fluid in the EDM process. The lowest value of S.R. (i.e., 4.5 microns) for EDM and Jatropha oil was achieved at current = 9 A, Ton = 30 μs, Toff = 12 μs, and Gap voltage = 50 V. As the values of current and pulse on time increase, the S.R. also increases. Current and pulse-on-time were the most significant parameters affecting S.R. Machine learning methods like linear regression, decision trees, and random forests were used to predict the surface roughness. Random forest modeling is highly accurate, with an R2 value of 0.89 and an MSE of 1.36% among all methods. Random forest models have better predictive capabilities and may be one of the best options for modeling complex EDM processes.

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“…Thus, the manufacturing process will be carried out efficiently and quickly when the processing parameters are optimized. In research into this area, discharge current (Ip), pulse on time (Ton), pulse off time (Toff), reference voltage and dielectric pressure are indicated as the most effective variable parameters on important performance results such as material removal rate (MRR), tool wear rate (TWR) and average surface roughness (Ra) [11,12]. The white layer, craters and peaks that appear on the machined surface after EDM are surface damages during thermal machining [13,14].…”

Section: Introduction (Gi̇ri̇ş)mentioning

confidence: 99%

Investigation of Workpiece and Tool Surface Quality in Electro Discharge Machining of Al 5083 Alloy Produced by Powder Metallurgy

IŞIK¹,

Çakıroğlu

2022

İmalat Teknolojileri Ve Uygulamaları

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Aluminum alloys are widely preferred in various fields such as aerospace, ship and automotive due to their lightness and relevant production cost. In this study, electro discharge technique was used in the processing of aluminum 5083 alloy (Al5083) produced by powder metallurgy method. The surface quality resulting from the experiments was investigated in terms of Ra, Rz and Rsm. Experimental studies were carried out according to Taguchi L9 orthogonal experimental design, using three different levels of discharge current, pulse on time and pulse off time parameters. As the discharge current increased, Ra and Rz increased, Rsm first decreased and then increased. As the pulse on time increased, Ra and Rz first increased and then decreased, and Rsm increased. When the pulse off time increased, Ra and Rz decreased and Rsm increased. As a result of the analysis of variance (ANOVA) performed to determine the effect rates of the variable parameters on the surface quality, the order of importance of the parameters was found to be discharge current, pulse off time and pulse on time. The effect of discharge current, which is the most effective parameter according to ANOVA, on Ra, Rz and Rsm was calculated as respectively 70.87%, 70.41% and 36.34%. Microscopic images taken from the tool (copper) and workpiece surface show that the craters and peaks formed by the spark effect are formed on both material surfaces.

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A simulation-based approach for modelling of fraction of energy transfer to workpiece in electrical discharge machining

Cited by 4 publications

References 0 publications

Effect of Faulty Solenoid Starter on the DC Series Motor Performance in Railway Industry

Effect of Faulty Solenoid Starter on the DC Series Motor Performance in Railway Industry

Surface roughness prediction of AISI D2 tool steel during powder mixed EDM using supervised machine learning

Investigation of Workpiece and Tool Surface Quality in Electro Discharge Machining of Al 5083 Alloy Produced by Powder Metallurgy

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