Finite element modeling and analysis of powder mixed electric discharge machining process for temperature distribution and volume removal considering multiple craters

Abstract

Powder mixed electric discharge machining (PMEDM) is one of the modern developments in electric discharge machining (EDM) process. In the present work, finite element modeling has been carried out considering randomly oriented multiple sparks during PMEDM. Transient thermal analysis is done to obtain temperature distribution, volume removal, and proportion of volume removed by melting and evaporation at different current, pulse on time and fraction of heat that enters to work piece. Gradually growing spark behavior and Gaussian distribution of heat source is used to simulate multiple craters. Temperature distribution along radial direction shows peak temperature at center of spark and thereafter a gradual decrease with increase in radial distance. Along depth direction temperature sharply decreases that forms wider craters with shallow depth in PMEDM. Peak temperature and volume removal increases with current more rapidly. Volume removal by melting is much higher than evaporation at lower current settings and with higher current almost equal amount of material is removed by melting and evaporation thus reducing the re-solidification of melted material. Current plays a significant role behind the contribution of material removal by evaporation followed by fraction of heat. Increase in pulse on duration increases the total volume of material removal however does not significantly increase the proportion of volume removal by vaporization.