Modeling of melt-pool formation and material removal in micro electro-discharge machining

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

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.

Original languageEnglish (US)
Title of host publicationASME 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
PublisherWeb Portal ASME (American Society of Mechanical Engineers)
ISBN (Electronic)9780791845806
DOIs
StatePublished - Jan 1 2014
EventASME 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 - Detroit, United States
Duration: Jun 9 2014Jun 13 2014

Publication series

NameASME 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
Volume1

Other

OtherASME 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
CountryUnited States
CityDetroit
Period6/9/146/13/14

Fingerprint

Electric discharge machining
Plasmas
Heat flux
Electrodes
Electric potential
Molten materials
Flow of fluids
Anodes
Heat transfer
Liquids
Experiments

ASJC Scopus subject areas

  • Industrial and Manufacturing Engineering

Cite this

Mujumdar, S. S., Curreli, D., Kapoor, S. G., & Ruzic, D. N. (2014). Modeling of melt-pool formation and material removal in micro electro-discharge machining. In 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 (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; Vol. 1). Web Portal ASME (American Society of Mechanical Engineers). https://doi.org/10.1115/MSEC2014-4108

Modeling of melt-pool formation and material removal in micro electro-discharge machining. / Mujumdar, Soham S.; Curreli, Davide; Kapoor, Shiv Gopal; Ruzic, David N.

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. Web Portal ASME (American Society of Mechanical Engineers), 2014. (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; Vol. 1).

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Mujumdar, SS, Curreli, D, Kapoor, SG & Ruzic, DN 2014, Modeling of melt-pool formation and material removal in micro electro-discharge machining. in 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. 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, vol. 1, Web Portal ASME (American Society of Mechanical Engineers), 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, Detroit, United States, 6/9/14. https://doi.org/10.1115/MSEC2014-4108
Mujumdar SS, Curreli D, Kapoor SG, Ruzic DN. Modeling of melt-pool formation and material removal in micro electro-discharge machining. In 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. Web Portal ASME (American Society of Mechanical Engineers). 2014. (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). https://doi.org/10.1115/MSEC2014-4108
Mujumdar, Soham S. ; Curreli, Davide ; Kapoor, Shiv Gopal ; Ruzic, David N. / Modeling of melt-pool formation and material removal in micro electro-discharge machining. 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. Web Portal ASME (American Society of Mechanical Engineers), 2014. (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).
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