Numerical Analysis of Flushing-Induced Thermal Cooling Including Debris Transport in Electrical Discharge Machining (EDM)

Gadeschi, Gonzalo Brito; Schneider, Sebastian; Mohammadnejad, M.; Meinke, Matthias; Klink, Andreas; Schröder, Wolfgang; Klocke, Fritz

doi:10.1016/j.procir.2017.03.325

Cited by 12 publications

(11 citation statements)

References 27 publications

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“…Further information on the governing equations can be found in Brito Gadeshi, Schneiders, et al (2017) and Schneiders et al (2017aSchneiders et al ( , 2017b. (Brito Gadeschi, Schneider, et al, 2017).…”

Section: Navier-stokes Equationsmentioning

confidence: 99%

“…is imposed, where the pressure is determined by the approximation of a vanishing normal gradient. The surface temperature T s on the workpiece which is sketched in Figure 1(a) is obtained from thermographic camera measurements by Brito Gadeschi, Schneider, et al (2017) the distribution of which is shown in Figure 1(b). It is prescribed using a steady Gaussian temperature profile with a peak temperature T max = 42 • C.…”

Section: Boundary Conditionsmentioning

confidence: 99%

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Direct particle–fluid simulation of flushing flow in electrical discharge machining

Gadeschi

Schilden

Albers

et al. 2021

Engineering Applications of Computational Fluid Mechanics

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The efficient removal of material debris by flushing is critical for the performance and the surface quality of the electrical discharge machining (EDM) manufacturing process. The particle concentration alters the thermal, mechanical, and electrical properties of the particle-dielectricum suspension and affects the manufacturing process and the surface quality by inducing high thermal loads. For the first time, we perform a direct particle-fluid simulation of the flushing cycle in a generic EDM cavity using a hierarchical Cartesian sharp-interface cut-cell method. The flow around each debris particle is completely resolved and the heat transfer between the particles and the fluid is taken into account. The rate of material removal and the cooling performance of the flushing mechanism are studied for three-volume loadings. The results show that the flow around the particles has a pronounced impact on the heat transfer between the dielectricum and the workpiece. A particle loading of 14% increases the mean heat transfer by approximately 16%. The particle loading also has a pronounced impact on the rate at which particles are flushed out of the cavity. Increasing the initial volume loading from 6% to 14% decreases the amount of particles that get flushed out of the cavity by 14%.

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Section: Navier-stokes Equationsmentioning

confidence: 99%

Section: Boundary Conditionsmentioning

confidence: 99%

Direct particle–fluid simulation of flushing flow in electrical discharge machining

Gadeschi

Schilden

Albers

et al. 2021

Engineering Applications of Computational Fluid Mechanics

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“…As a result, alternative flushing methods have been proposed, including linear motor equipped [14], mono hole inner flushing [15], side suction flushing [16], and modified electrodes [17]. In [14][15][16][17], single-channel, multi-channel, and channel-less cylindrical electrodes were comparatively investigated. The results showed that compared to the multi-channel electrode, the single-channel electrode is less ideal for blind-hole drilling due to spike at the center of the hole base.…”

Section: Introductionmentioning

confidence: 99%

Effects of Side Flushing and Multi-Aperture Inner Flushing on Characteristics of Electrical Discharge Machining Macro Deep Holes

Chuvaree

Kanlayasiri

2021

Metals

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This research investigates the effect of machining parameters on material removal rate, electrode wear ratio, and gap clearance of macro deep holes with a depth-to-diameter ratio over four. The experiments were carried out using electrical discharge machining with side flushing and multi-aperture flushing to improve the machining performance and surface integrity. The machining parameters were pulse on-time, pulse off-time, current, and electrode rotation. Response surface methodology and the desirability function were used to optimize the electrical discharge machining parameters. The results showed that pulse on-time, current, and electrode rotation were positively correlated with the material removal rate. The electrode wear ratio was inversely correlated with pulse on-time and electrode rotation but positively correlated with current. Gap clearance was positively correlated with pulse on-time but inversely correlated with pulse off-time, current, and electrode rotation. The optimal machining condition of electrical discharge machining with side flushing was 100 µs pulse on-time, 20 µs pulse off-time, 15 A current, and 70 rpm electrode rotation; and that of electrical discharge machining with multi-aperture flushing was 130 µs, 2 µs, 15 A, and 70 rpm. The novelty of this research lies in the use of multi-aperture flushing to improve the machining performance, enable a more uniform GC profile, and minimize the incidence of recast layer.

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“…Electrical Discharge Machining (EDM) erodes a workpiece material by applying electric sparks regardless of the material’s mechanical properties, and it has shown a good potential in producing real, 3-D, intricate features in advanced difficult-to-cut materials [5,6,7]. In EDM, the mechanism eroding the workpiece material is a thermoelectric process between electrical, conductive electrodes (the tool and workpiece).…”

Section: Introductionmentioning

confidence: 99%

“…The local high temperature melts both the workpiece and tool [8]. Then, the eroded material solidifies in the form of debris (solidified eroded particles), and finally, the flushing of a dielectric fluid evacuates the debris [7]. This process occurs repeatedly, enabling a continuous machining of the workpiece.…”

Section: Introductionmentioning

confidence: 99%

Self-Flushing in EDM Drilling of Ti6Al4V Using Rotating Shaped Electrodes

Goiogana

Elkaseer

2019

Materials

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This article reports an experimental investigation of the efficacy of self-flushing in the Electrical Discharge Machining (EDM) process in terms of tool wear rate (TWR), hole taper angle and material removal rate (MRR). In addition to a plain cylindrical shape, electrodes of different cross sections (slotted cylindrical, sharp-cornered triangular, round-cornered triangular, sharp-cornered square, round-cornered square, sharp-cornered hexagonal and round-cornered hexagonal) were designed as a means of inducing debris egress and then fabricated in graphite. EDM drilling trials using the rotating shaped electrodes were carried out on a Ti6Al4V workpiece. The results revealed that, although a low TWR and minimum hole taper angle were achieved using a plain cylindrical electrode, the usage of rotating shaped electrodes provided self-flushing of the dielectric fluid during the EDM process, which led to an improvement in MRR compared to that achieved with a plain cylindrical electrode. Besides, in general, the electrodes with rounded corners are associated with a lower TWR, a lower hole taper angle and a higher MRR when compared to the electrodes with sharp corners. Considering these results, it was concluded that different process attributes, i.e., TWR, hole taper angle and MRR, are all greatly affected by the electrode shape, and thus, the proper selection of the electrode shape is a precondition to attain a specific response from the EDM process.

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Numerical Analysis of Flushing-Induced Thermal Cooling Including Debris Transport in Electrical Discharge Machining (EDM)

Cited by 12 publications

References 27 publications

Direct particle–fluid simulation of flushing flow in electrical discharge machining

Direct particle–fluid simulation of flushing flow in electrical discharge machining

Effects of Side Flushing and Multi-Aperture Inner Flushing on Characteristics of Electrical Discharge Machining Macro Deep Holes

Self-Flushing in EDM Drilling of Ti6Al4V Using Rotating Shaped Electrodes

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