FE Simulation of material removal and surface properties for EDM during single and multiple spark occurrences

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EDM represents an effective machining process for hard-to-machine materials. Although EDM has many advantages, it lacks well-developed technological base and level of fundamental understanding that characterizes other metal cutting technologies. This has limited the development of CAE based modeling platforms that enable users to predict workpiece properties. While EDM related research is on-going, a challenge in developing comprehensive process models is that EDM is a complex process based on complex effects. However, it is hypothesized that material removal and surface properties can be modeled using simplified representations considering thermo-mechanical effects. In this study, the objective is to develop FE model to simulate material removal and predict surface topography and residual stresses for workpiece surfaces. This will be scaled up to model multiple spark occurrences. A two-dimensional model representing single spark occurrences for L6 steel has been developed using DEFORM v9.0. The model incorporates Gaussian heat source and time-dependent conditions. The FE model has been found to have good agreement with a test condition using single spark. Work is presently underway to validate model robustness under other conditions based on experiments using micro EDM machine. Once this is completed, work will be undertaken to develop modeling strategy for multiple spark occurrences.

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Journal: TechConnect Briefs
Volume: 4, Advanced Manufacturing, Electronics and Microsystems: TechConnect Briefs 2015
Published: June 14, 2015
Pages: 17 - 20
Industry sector: Advanced Materials & Manufacturing
Topic: Advanced Manufacturing
ISBN: 978-1-4987-4730-1