TY - GEN
T1 - Modeling of melt-pool formation and material removal in micro electro-discharge machining
AU - Mujumdar, Soham S.
AU - Curreli, Davide
AU - Kapoor, Shiv Gopal
AU - Ruzic, David N
N1 - Publisher Copyright:
Copyright © 2014 by ASME.
PY - 2014
Y1 - 2014
N2 - This paper presents a μ-EDM melt-pool model to predict workpiece (anode) material removal from a single discharge μ-EDM process. To model the melt-pool heat transfer and fluid flow equations are solved in the domain containing dielectric and workpiece material. A level set method is used to identify solid and liquid fractions of the workpiece material when the material is molten by μ-EDM plasma heat flux. The plasma heat flux, plasma pressure and the radius of the plasma bubble have been estimated by a μ-EDM plasma model and serve as inputs to the melt-pool model to predict the volume of material removed from the surface of the workpiece. Experiments are carried out to study the effect of inter-electrode voltage and gap distance on the crater size. For inter-electrode voltage in the range of 100-150 V and gap distance of 0:5-2 μm, the model predicts crater diameter in the range of 150-165 μm and maximum crater depth of 25-35 μm for discharge duration of 5 μs. The crater sizes for most of experimental craters at higher gap distances show good agreement with the simulated crater shapes. However, at lower gaps, the model over-predicts the crater size.
AB - This paper presents a μ-EDM melt-pool model to predict workpiece (anode) material removal from a single discharge μ-EDM process. To model the melt-pool heat transfer and fluid flow equations are solved in the domain containing dielectric and workpiece material. A level set method is used to identify solid and liquid fractions of the workpiece material when the material is molten by μ-EDM plasma heat flux. The plasma heat flux, plasma pressure and the radius of the plasma bubble have been estimated by a μ-EDM plasma model and serve as inputs to the melt-pool model to predict the volume of material removed from the surface of the workpiece. Experiments are carried out to study the effect of inter-electrode voltage and gap distance on the crater size. For inter-electrode voltage in the range of 100-150 V and gap distance of 0:5-2 μm, the model predicts crater diameter in the range of 150-165 μm and maximum crater depth of 25-35 μm for discharge duration of 5 μs. The crater sizes for most of experimental craters at higher gap distances show good agreement with the simulated crater shapes. However, at lower gaps, the model over-predicts the crater size.
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U2 - 10.1115/MSEC2014-4108
DO - 10.1115/MSEC2014-4108
M3 - Conference contribution
AN - SCOPUS:84908880954
T3 - ASME 2014 International Manufacturing Science and Engineering Conference, MSEC 2014 Collocated with the JSME 2014 International Conference on Materials and Processing and the 42nd North American Manufacturing Research Conference
BT - ASME 2014 International Manufacturing Science and Engineering Conference, MSEC 2014 Collocated with the JSME 2014 International Conference on Materials and Processing and the 42nd North American Manufacturing Research Conference
PB - Web Portal ASME (American Society of Mechanical Engineers)
T2 - ASME 2014 International Manufacturing Science and Engineering Conference, MSEC 2014 Collocated with the JSME 2014 International Conference on Materials and Processing and the 42nd North American Manufacturing Research Conference
Y2 - 9 June 2014 through 13 June 2014
ER -