Abstract
This study reports the results of a finite element simulation of powder mixed electric discharge machining process for H11 Hot Die steel material using relevant boundary conditions and reasonable assumptions. The crater shape was developed using simulated temperature profiles to estimate the volume removed in a single crater. The temperature distribution on the workpiece was used to predict the cooling rate and calculate the stresses generated due to thermal loading. Subsequently, the simulation results were experimentally validated by physically measuring the crater shape and volume. From the results it was concluded that about 25% of heat is transmitted to the workpiece during machining at the process conditions used in the experiment. The microscopic pictures showed bigger craters with increase in current. The machined surface showed overlapping craters with surface cracks suggesting a high cooling rate.
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