Thermophysical-Based Modeling of Material Removal in Powder Mixed Near-Dry Electric Discharge Machining
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JMEPEG https://doi.org/10.1007/s11665-020-05110-3
Thermophysical-Based Modeling of Material Removal in Powder Mixed Near-Dry Electric Discharge Machining Sanjay Sundriyal, Jitender Yadav, R.S. Walia
, Vipin, and Rajesh Kumar
(Submitted April 2, 2020; in revised form July 26, 2020) 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 NDEDM. 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. Keywords
Gaussian heat distribution, inter-electrode gap, material removal rate, near-dry EDM, powder mixed near-dry EDM
1. Introduction Electric discharge machining is the most versatile nontraditional machining process which is widely used in aerospace, automobile, power-plant, casting, injection molding and forming industries. This machining process comes with peculiarity that it can machine any material irrespective of its physical properties like hardness, toughness, brittleness, etc. A major feature of this process is the erosion of workpiece material due to the action of highly energized plasma channel. EDM also suffers from serious limitations like low MRR, poor efficiency and poor surface finish. This encouraged researchers to better this machining method by using the idea of hybridizing the EDM process with other conventional and non-conventional machining processes. Unlike EDM, powder mixed near-dry EDM has many advantages like low consumption of dielectric oil along with metallic powders (Ref 1-4), relatively more efficiency such as increase in productivity and high surface quality and low emission of toxic effluents (Ref 58). Provision of metallic powder particles in dielectric medium reduces the dielectric strength. This further helps in uniform distribution of plasma heat in all directions. This resulted in the formation of stable arc and hence an increase in MRR (Ref 9). Analytical modeling of the electro-thermal erosion process has been performed by many researchers (Ref 10-12). Some Sanjay Sundriyal, Jitender Yadav, Vipin, and Rajesh Kumar, Delhi Tech
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