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Thermophysical-Based Modeling of Material Removal in Powder Mixed Near-Dry Electric Discharge Machining
Journal of Materials Engineering and Performance ( IF 2.3 ) Pub Date : 2020-09-18 , DOI: 10.1007/s11665-020-05110-3
Sanjay Sundriyal , Jitender Yadav , R. S. Walia , Vipin , Rajesh Kumar

Electrical discharge machining (EDM) is a non-conventional method of machining hard materials with intricate shapes. Near-dry electric discharge machining (ND-EDM) is an advanced method of EDM which is eco-friendly and is more efficient in terms of material removal rate (MRR) than traditional EDM. In this research, an approach has been made to perform a new electrical discharge machining operation on EN-31 steel which utilizes metallic powder as an additive along with a gaseous dielectric (for example air) in ND-EDM. This advanced method of machining is known as powder mixed near-dry EDM. This study involves modeling for output process parameter—Material Removal Rate. The mathematical model was developed using the approach of Gaussian heat distribution. FEM modeling was done on ANSYS WORKBENCH 16.0 module. The experiments were performed and comparative study was done between the results obtained by modeling and experiments. The maximum experimental MRR was 7.68 mm3/min, and the error percentage between experimental, mathematical and FEM was under 30%. It was concluded that the modeling was done successfully and results obtained do comply with the methodology of the research.



中文翻译:

基于热物理的粉末混合近干放电加工材料去除模型

放电加工(EDM)是一种非常规方法,用于加工形状复杂的硬质材料。近干放电加工(ND-EDM)是一种先进的电火花加工方法,具有生态友好性,并且在材料去除率(MRR)方面比传统电火花加工效率更高。在这项研究中,已采取一种对EN-31钢执行新的放电加工操作的方法,该方法利用金属粉末作为添加剂以及ND-EDM中的气态电介质(例如空气)。这种先进的加工方法称为粉末混合近干EDM。这项研究涉及对输出过程参数(材料去除率)进行建模。数学模型是使用高斯热分布方法开发的。有限元建模是在ANSYS WORKBENCH 16.0模块上完成的。进行了实验,并且在通过建模和实验获得的结果之间进行了比较研究。最大实验MRR为7.68毫米3 / min,并且实验,数学和有限元方法之间的误差百分比低于30%。结论是,建模成功完成,并且获得的结果符合研究方法。

更新日期:2020-09-20
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