Die-Sinking EDM Simulation Coupled by Fluid Flow Analysis in Discharge Gap

Abstract

This paper describes a die-sinking EDM simulation which can simulate the wear of tool electrode with sharp edges and the distribution of debris particles concentration in the machining gap. This simulation is based on the discharge location searching algorithm to reproduce the gap phenomena caused by every pulse discharge. The algorithm is a simple repetition of the routine which is composed of: 1) determining the next discharge location, 2) removing the tool electrode and work piece electrodes, 3) distributing debris particles, and 4) feeding the tool electrode. This algorithm was modified to simulate the removal of surfaces with large inclination, lateral surfaces and edge portions of the tool electrode. Moreover, a method to calculate the debris particles concentration in the gap extended three dimensionally was developed. Thus, the wear of tool electrode with sharp edges was simulated combining the discharge location searching algorithm with the 3D calculation of debris concentration. Simulation results agreed with experimental results especially in the case of using brass as the tool electrode material with which deposition of carbon on the tool electrode is negligibly small.