This paper presents a μ – EDM melt-pool model to predict workpiece (anode) material removal from a single discharge μ – EDM process. To model the melt-pool heat transfer and fluid flow equations are solved in the domain containing dielectric and workpiece material. A level set method is used to identify solid and liquid fractions of the workpiece material when the material is molten by μ – EDM plasma heat flux. The plasma heat flux, plasma pressure and the radius of the plasma bubble have been estimated by a μ – EDM plasma model and serve as inputs to the melt-pool model to predict the volume of material removed from the surface of the workpiece. Experiments are carried out to study the effect of inter-electrode voltage and gap distance on the crater size. For inter-electrode voltage in the range of 100–150 V and gap distance of 0.5–2 μm, the model predicts crater diameter in the range of 150–165 μm and maximum crater depth of 25–35 μm for discharge duration of 5 μs. The crater sizes for most of experimental craters at higher gap distances show good agreement with the simulated crater shapes. However, at lower gaps, the model over-predicts the crater size.
- Manufacturing Engineering Division
Modeling of Melt-Pool Formation and Material Removal in Micro Electro-Discharge Machining
Mujumdar, SS, Curreli, D, Kapoor, SG, & Ruzic, D. "Modeling of Melt-Pool Formation and Material Removal in Micro Electro-Discharge Machining." Proceedings of the ASME 2014 International Manufacturing Science and Engineering Conference collocated with the JSME 2014 International Conference on Materials and Processing and the 42nd North American Manufacturing Research Conference. Volume 1: Materials; Micro and Nano Technologies; Properties, Applications and Systems; Sustainable Manufacturing. Detroit, Michigan, USA. June 9–13, 2014. V001T03A014. ASME. https://doi.org/10.1115/MSEC2014-4108
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