Simulation of flow-field and debris temperature analysis in micro-electrical discharge milling using slotted tools

Abstract

In micro-electrical discharge milling (μED-milling), the rotation and forward feed motion of the tool is the key element responsible for evacuation of the debris particles. The inability to eliminate debris from the interelectrode gap (IEG) causes secondary discharge, short-circuit, and hampers removal rate. This problem is predominant in electrical discharge machining (EDM) where the tool is stationary. Various methods have been devised in the literature to boost debris removal from the IEG. In this paper, the use of a slotted tool with different cross-sections is proposed. The dielectric flow-field, debris trajectory, and cooling rate are calculated using computational fluid dynamics (CFD). Effect of different parameters such as tool rotation, gap size, jet velocity, the shape of slots on the dielectric flow is determined. The slots on the tool create turbulence which enhances the debris removal from the IEG. It also provides the space to accumulate the debris particles, thereby increasing the removal rate. The variation in the dielectric flow-field greatly affects the debris flushing from the IEG. The trajectory of the debris particles depends on their initial position in the IEG and they cool rapidly, which is validated using simulation and mathematical approach.

CFD Simulation and Optimization of the Leaf Collecting Mechanism for the Riding-Type Tea Plucking Machine

“…It mainly determines the turbulence viscosity coefficient by solving two additional equations: the k equation (k is turbulence kinetic energy) and ε equation (Epsilon, dissipation rate of turbulence kinetic energy), and then solves the turbulence stress. When the standard k-ε model is used to solve the real turbulence problem, the governing equations include the continuity equation, momentum equation, energy equation, k-ε equation, and viscosity coefficient equation [22]. Suppose that the components of a fluid element per unit mass on each coordinate axis are denoted as x, y, and z, respectively:…”