Research on the energy distribution of micro EDM by utilization of electro-thermal model

Wang, Kan; Zhang, Qinhe; Zhu, Guang; Liu, Qingyu; Huang, Yuhua; Zhang, Jianhua

doi:10.1007/s00170-017-0822-z

Cited by 21 publications

(9 citation statements)

References 22 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…In the process of EDM, the diameter of the discharge channel is difficult to measure directly because of the short discharge time and the strong light effect. In reference [2], the empirical equation of the radius of the discharge channel was deduced by observing actual discharge craters with SEM, as shown in Equation (13). The radius of the discharge channel (R p : µm) is a function of the pulse current (I: A) and the pulse-on time (T on : µs).…”

Section: Radius Of the Discharge Channelmentioning

confidence: 99%

“…However, the discharge energy distribution coefficient that varies with the discharge parameters has gradually replaced the fixed partition coefficient. In reference [2], by combining temperature field simulation with the experimental measurements, the ratio of the discharge energy absorbed by the workpiece was obtained, which was a function of the pulse current and pulse-on time, as shown in Equation ( 14). The proportion of energy absorbed by the workpiece in this study is consistent with that in reference [2].…”

Section: Proportion Of the Discharge Energy Absorbed By The Workpiecementioning

confidence: 99%

“…In this study, the predicted precision of the thermal model for micro/nano-EDM considering the non-Fourier effect was evaluated by comparing the sizes of experimental discharge craters. Figure 4 shows the schematic diagram of the single-pulse discharge machining system [2]. The power supply of a single-pulse discharge machining system was a DC power supply.…”

Section: Experimental Configurationmentioning

confidence: 99%

“…Due to its advantages of ignoring material hardness, the ability to machine a complex curved surface, and no cutting stress, EDM is widely used in aerospace, instruments, the molding industry, and other precision manufacturing fields [1,2]. The discharge energy of a short-period single pulse is lower in micro/nano-EDM.…”

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

A New Thermal Model for Predicted Discharge Craters in Micro/Nano-EDM Considering the Non-Fourier Effect

Chen

Zhou

et al. 2022

Crystals

View full text Add to dashboard Cite

Micro/nano-electrical discharge machining is an alternative preparation method for surface micro/nano-structures, but it is difficult to precisely control the size of the micro/nano-structures due to its unclear material removal mechanism. Thus, it is useful to study its machining mechanism to achieve high-efficiency and controlled processing. At present, most of the established EDM thermal models for predicting the discharge crater size are based on the classical Fourier heat conduction law, assuming that the conduction velocity of heat energy is infinite. However, the single-pulse discharge time of micro/nano-EDM is transitory (<1 μs), and thus, the steady state heat balance condition cannot be achieved in a single-pulse discharge time. In order to predict the size of the micro/nano electrical discharge craters more accurately, the non-Fourier effect was considered to study the temperature field distribution of micro/nano-EDM of single-pulse discharge machining. Firstly, the classical Fourier heat conduction law was modified by introducing a relaxation time. Secondly, several key factors were considered to establish the thermal model of micro/nano-EDM in single-pulse discharge machining. Subsequently, numerical simulation software was used to solve the thermal model for obtaining the temperature field distribution of the workpiece material and predicting the size of the discharge craters. Finally, the predicting accuracy of the new thermal model was evaluated by comparing the relative error between the simulated values and experimental values. The comparison results show that considering the non-Fourier effect can reduce the average error of the thermal model from 33% to 10%. The non-Fourier effect is more obvious under the shorter discharge time of a single pulse.

show abstract

Section: Radius Of the Discharge Channelmentioning

confidence: 99%

Section: Proportion Of the Discharge Energy Absorbed By The Workpiecementioning

confidence: 99%

Section: Experimental Configurationmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

A New Thermal Model for Predicted Discharge Craters in Micro/Nano-EDM Considering the Non-Fourier Effect

Chen

Zhou

et al. 2022

Crystals

View full text Add to dashboard Cite

show abstract

“…However, it is difficult to obtain the single discharge energy directly by measurement at present because the principle of the VHF pulse generator is very different. Some scholars [29,30] measured the size of the craters generated by single-pulse experiments and established electro-thermal models for micro-EDM.…”

Section: Electro-thermal Model Of Vhf Micro-edmmentioning

confidence: 99%

Theoretical and experimental investigation into machining characteristics Of VHF micro-EDM

Zhang

et al. 2021

Int J Adv Manuf Technol

View full text Add to dashboard Cite

To further explore the machining characteristics of very high-frequency micro-electrical discharge machining (VHF micro-EDM), the range of radio-frequency (RF) power amplifier was expanded to 110 MHz, and the power of the RF power amplifier was also greatly increased up to 91 W. The principle of the VHF pulse generator was discussed in detail, and an electrothermal model suitable for VHF micro-EDM was established to determine the diameter of the plasma channel and the energy distribution ratio. Experimental studies for VHF micro-EDM were also carried out, and the effects of power and frequency on machining characteristics were then analysed and discussed. The results show that at the same frequency, the higher the power is, the higher the material removal rate (MRR) and the larger the number of discharge craters. At the same power, the MRR and the size of discharge craters both first increase and then decrease with increasing frequency and reach the maximum value at 65 MHz. For the copper workpiece, when the frequency is 110 MHz and the total power of the power amplifier is 8.0 W, 5.6% of the energy is used for the material removal of the workpiece, and the finest processing surface is obtained with the surface roughness Ra=12 nm. The average diameter of the discharge craters is as small as 0.268 μm, and the diameter of the plasma channel is only 0.350 μm. In addition, the effects of different workpiece materials and dielectric fluids are also analysed in this paper.

show abstract

Design and Test of Pulsed Power Supply

Tong¹,

Li²

2022

Servo Scanning 3D Micro Electro Discharge Machining

View full text Add to dashboard Cite

Research on the energy distribution of micro EDM by utilization of electro-thermal model

Cited by 21 publications

References 22 publications

A New Thermal Model for Predicted Discharge Craters in Micro/Nano-EDM Considering the Non-Fourier Effect

A New Thermal Model for Predicted Discharge Craters in Micro/Nano-EDM Considering the Non-Fourier Effect

Theoretical and experimental investigation into machining characteristics Of VHF micro-EDM

Design and Test of Pulsed Power Supply

Contact Info

Product

Resources

About