Electrical discharge machining (EDM) is an important and cost-effective manufacturing process for machining electrically conductive materials irrespective of their hardness in various industries including automotive, aerospace, biomedical, and semiconductor. The applications of EDM are not just limited to the machining of hard materials, but also cover the production of difficult-to-make microstructures for micro-molds, fuel injection nozzles, spinneret holes, etc. However, although EDM is widely used, scientific knowledge of the process is still limited. The complex nature of the process involves simultaneous interaction of thermal, mechanical, chemical, and electrical phenomena, which makes process modeling very difficult. New contribution to the simulation and modeling of the formation of micro-holes during EDM process is presented in this paper. Mathematical modeling of the evolution of the machined surface at electrical discharge machining using ablation of the workpiece material was carried out. In contrast to the known models of EDM, the proposed model allows to determine the location of the center of the discharge channel, both on the surface of the workpiece and on the surface of the tool-electrode, which makes it possible to predict the wear of the tool-electrode during machining. The obtained results make it possible to predict the shape, size, and surface roughness of the micro-hole and the performance of EDM.
Evolution of machined surface Discharge Modeling electrical discharge machining Erosive crater Roughness Temperature
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The study was funded by RFBR and Tula region according to the research project No. 19-48-710009 p_a.
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