Abstract
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.
This is a preview of subscription content, log in via an institution to check access.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Eliseev LS, Boitsov AG, Krymov VV, Khvorostukhin LA (2003) Tekhnologiya proizvodstva aviacionnykh gazoturbinnykh dvigatelei (Technology of production of aviation gas turbine engines). Mashinostroenie, Moscow
Hocheng H, Tsai HY (2013) Advanced analysis of nontraditional machining. Springer, New York
Kibria G, Jahan MP, Bhattacharyya B (2019) Micro-electrical discharge machining processes. Springer, Singapore
Revaz B, Witz G, Flukiger R (2005) Properties of the plasma channel in liquid discharges inferred from cathode local temperature measurements. J Appl Phys 98:113305
Kunieda M, Lauwers B, Rajurkar KP, Schumacher BM (2005) Advancing EDM through fundamental insight into the process. CIRP Ann-Manuf Techn 54(2):64–87
Joshi SN, Pande SS (2010) Thermo-physical modeling of die-sinking EDM process. J Manuf Process 12:45–56
Hoang KT, Gopalan SK, Yang SH (2015) Study of energy distribution to electrodes in a micro-EDM process by utilizing the electro-thermal model of single discharges. J Mech Sci Technol 29(1):349–356
Assarzadeh S, Ghoreishi M (2017) Prediction of root mean square surface roughness in low discharge energy die-sinking EDM process considering the effects of successive discharges and plasma flushing efficiency. J Manuf Process 30:502–515
Jeong YH, Min BK (2007) Geometry prediction of EDM-drilled holes and tool electrode shapes of micro-EDM process using simulation. Int J Mach Tool Manu 47(12):1817–1826
Tan PC, Yeo SH (2008) Modelling of overlapping craters in micro-electrical discharge machining. J Phys D Appl Phys 41(20):205302
Izquierdo B, Sanchez JA, Plaza S, Pombo I, Ortega N (2009) A numerical model of the EDM process considering the effect of multiple discharges. Int J Mach Tool Manu 49(3):220–229
Izquierdo B, Sánchez JA, Ortega N, Plaza S, Pombo I (2011) Insight into fundamental aspects of the EDM process using multidischarge numerical simulation. Int J Adv Manuf Tech 52(1–4):195–206
Hinduja S, Kunieda M (2013) Modelling of ECM and EDM processes. CIRP Ann-Manuf Techn 62(2):775–797
Somashekhar KP, Panda S, Mathew J, Ramachandran N (2015) Numerical simulation of micro-EDM model with multi-spark. Int J Adv Manuf Tech 76(1–4):83–90
Huang H, Zhang Z, Ming W, Xu Z, Zhang Y (2017) A novel numerical predicting method of electric discharge machining process based on specific discharge energy. Int J Adv Manuf Tech 88(1):409–424
Feng X, Wong YS, Hong GS (2016) Characterization and geometric modeling of single and overlapping craters in micro-EDM. Mach Sci Technol 20(1):79–98
Lyubimov VV, Volgin VM, Gnidina IV, Salomatnikov MS (2018) Formation of the workpiece shape and surface finish during electrical discharge machining. Procedia CIRP 68:319–324
Frei W (2017) How to compute distances between objects in COMSOL multiphysics: Comsol Blog. https://www.comsol.com/blogs/how-to-compute-distances-between-objects-in-comsol-multiphysics. Accessed 3 Sept 2018
Weingärtnera E, Kustera F, Wegenera K (2012) Modeling and simulation of electrical discharge machining. Procedia CIRP 2:74–78
Frei W (2016) Modeling thermal ablation for material removal: Comsol Blog. https://www.comsol.com/blogs/modeling-thermal-ablation-for-material-removal. Accessed 3 Sept 2018
Acknowledgements
The study was funded by RFBR and Tula region according to the research project No. 19-48-710009 p_a.
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2020 Springer Nature Switzerland AG
About this paper
Cite this paper
Nguyen, T.D., Volgin, V.M., Lyubimov, V.V. (2020). Simulation of Electrical Discharge Machining of Micro-holes. In: Radionov, A., Kravchenko, O., Guzeev, V., Rozhdestvenskiy, Y. (eds) Proceedings of the 5th International Conference on Industrial Engineering (ICIE 2019). ICIE 2019. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-030-22063-1_41
Download citation
DOI: https://doi.org/10.1007/978-3-030-22063-1_41
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-030-22062-4
Online ISBN: 978-3-030-22063-1
eBook Packages: EngineeringEngineering (R0)