Journal ArticleDOI
Thermal stresses due to electrical discharge machining
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TLDR
In this paper, a finite element model has been developed to estimate the temperature field and thermal stresses due to Gaussian distributed heat flux of a spark during electrical discharge machining (EDM).Abstract:
The high temperature gradients generated at the gap during electrical discharge machining (EDM) result in large localized thermal stresses in a small heat-affected zone. These thermal stresses can lead to micro-cracks, decrease in strength and fatigue life and possibly catastrophic failure. A finite element model has been developed to estimate the temperature field and thermal stresses due to Gaussian distributed heat flux of a spark during EDM. First, the developed code calculates the temperature in the workpiece and then the thermal stress field is estimated using this temperature field. The effects of various process variables (current and duty cycle) on temperature distribution and thermal stress distribution have been reported. The results of the analysis show high temperature gradient zones and the regions of large stresses where, sometimes, they exceed the material yield strength.read more
Citations
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Journal ArticleDOI
EDM simulation: finite element-based calculation of deformation, microstructure and residual stresses
TL;DR: In this paper, a finite element-based model for the electric discharge machining (EDM) process is presented, which uses process parameters such as power input, pulse duration, etc., to predict the transient temperature distribution, liquid-and solid-state material transformation, and residual stresses that are induced in the workpiece as a result of a single-pulse discharge.
Journal ArticleDOI
Thermal modeling of the material removal rate and surface roughness for die-sinking EDM
TL;DR: In this article, a simple thermal based model has been developed for the determination of the material removal rate and the average surface roughness achieved as a function of the process parameters, which predicts that the increase of the discharge current, the arc voltage or the spark duration results in higher material removal rates and coarser workpiece surfaces.
Journal ArticleDOI
A finite element model of EDM based on the Joule effect
TL;DR: In this paper, a thermal-electrical model was developed for sparks generated by electrical discharge in a liquid media, where a cylindrical shape has been used for the discharge channel created between the electrodes.
Journal ArticleDOI
A numerical model of the EDM process considering the effect of multiple discharges
TL;DR: In this article, a new contribution to the simulation and modelling of the electrical discharge machining process is presented, where temperature fields within the workpiece generated by the superposition of multiple discharges are numerically calculated using a finite difference schema.
Journal ArticleDOI
Numerical simulation of powder mixed electric discharge machining (PMEDM) using finite element method
TL;DR: An axisymmetric two-dimensional model for powder mixed electric discharge machining (PMEDM) has been developed using the finite element method (FEM) and validated by comparing the theoretical MRR with the experimental one obtained from a newly designed experimental setup developed in the laboratory.
References
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Book
An Introduction to the Finite Element Method
TL;DR: Second-order Differential Equations in One Dimension: Finite Element Models (FEM) as discussed by the authors is a generalization of the second-order differential equation in two dimensions.
Book
Theory of thermal stresses
TL;DR: Theory of thermal stresses, Theory of Thermal Stresses, this paper, Theory of thermal stress, and thermal stresses theory, thermal stresses and thermal stress theory in literature, 2015.
Journal ArticleDOI
Theoretical models of the electrical discharge machining process. I. A simple cathode erosion model
TL;DR: A simple cathode erosion model for the electrical discharge machining (EDM) process is presented in this article, where a constant fraction of the total power supplied to the gap is transferred to the cathode over a wide range of currents.
Journal ArticleDOI
Theoretical models of the electrical discharge machining process. II. The anode erosion model
TL;DR: In this paper, an erosion model for the anode material is presented, which is capable of showing, via determined migrating melt fronts, the rapid melting of the anodic material as well as the subsequent resolidification of the material foation from plasma dynamics modeling.