TAILIEUCHUNG - A numerical model of the EDM process considering the effect of multiple discharges

(BQ)In this paper a new contribution to the simulation and modelling of the EDM process is presented. Temperature fields within the workpiece generated by the superposition of multiple discharges, as it happens during an actual EDM operation, are numerically calculated using a finite difference schema. The characteristics of the discharge for a given operation, namely energy transferred onto the workpiece, diameter of the discharge channel and material removal efficiency can be estimated using inverse identification from the results of the numerical model. The model has been validated through industrial EDM tests, showing that it can efficiently predict material removal rate and surface roughness with errors below 6%. | ARTICLE IN PRESS International Journal of Machine Tools & Manufacture 49 (2009) 220–229 Contents lists available at ScienceDirect International Journal of Machine Tools & Manufacture journal homepage: A numerical model of the EDM process considering the effect of multiple discharges ´ B. Izquierdo Ã, . Sanchez, S. Plaza, I. Pombo, N. Ortega Faculty of Engineering of Bilbao, Alameda de Urkijo s/n, 48013 Bilbao, Spain a r t i c l e in f o a b s t r a c t Article history: Received 18 February 2008 Received in revised form 17 November 2008 Accepted 18 November 2008 Available online 3 December 2008 The electrical discharge machining (EDM) process is, by far, the most popular amongst the nonconventional machining processes. The technology is optimum for accurate machining of complex geometries in hard materials, as those required in the tooling industry. However, although a large number of EDM machines are sold every year, 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 modelling very difficult. In this paper a new contribution to the simulation and modelling of the EDM process is presented. Temperature fields within the workpiece generated by the superposition of multiple discharges, as it happens during an actual EDM operation, are numerically calculated using a finite difference schema. The characteristics of the discharge for a given operation, namely energy transferred onto the workpiece, diameter of the discharge channel and material removal efficiency can be estimated using inverse identification from the results of the numerical model. The model has been validated through industrial EDM tests, showing that it can efficiently predict material removal rate and surface roughness with errors below 6%. & 2008 Elsevier Ltd. All rights reserved. Keywords: EDM Thermal model Roughness

• Cơ khí - Chế tạo máy
• The electrical discharge machining
• The EDM process
• The effect of multiple discharges
• Thermal model
• Roughness prediction
• Material removal rate
• Understanding electrical discharge machining
• Electrical discharge machining
• Various Electric Discharge Machines
• Keeping Abreast With EDM Technology
• The Machining Revolution
• A strip electrode
• The machining principle
• Surface modification
• Powder metallurgy electrodes
• Surface finish
• Electrode wear
• Inconel 718
• Response Surface Methodology
• Multi Objective Particle SwarmOptimization
• The EDM processes
• Process parameters
• Stainless steel
• Optimization of machining parameters
• Fuzzy logic analysis
• Analysis of variance
• Machining precision and accuracy
• Green manufacturing
• Multi attribute decision making
• Fuzzy TOPSIS methods
• Silicon carbide
• Die sinking EDM
• Ceramic composite
• Artificial neural network
• Multi objective optimization
• Genetic algorithm
• Orthogonal array
• Statistical analyses
• Decision making model for green EDM
• Electro Discharge Machining
• Polynomial model
• Neuro fuzzy model
• Non conventional machining
• Journal of Science and Technology
• Analysis of surface layers of hot
• Analysis of surface layers of hot – forging die
• Hot forging die following die sinking
• Taguchi methods
• Ideal function
• Energy distribution
• Sinking electro discharge machining
• Mathematical model
• Ultrasonic vibration
• Dry EDM
• Powder additives
• EDM in water
• Multi response optimization
• Powder mixed electrical discharge machining
• Surface micro hardness
• Pulse on time
• Pulse off time
• Tool steel
• Surface roughness
• Examination of machining parameters
• EDM of tool steel
• Metal matrix composite
• Temperature stability
• Duty factor
• Titanium alloys
• Electrical process parameters
• State of art in EDM process
• Process parameters of wire cut
• 90CrSi tool steel
• Wire cut EDM
• Tool steel machining
• AISI P20 tool steel
• Fuzzy TOPSIS
• Sensitivity analysis
• Predictive model
• Discrimination of discharging pulses
• System identification