Abstract
In this paper, a finite element method (FEM) has been developed for 2D axisymmetric thermal model for the prediction of temperature distribution profile on workpiece during electro discharge machining and for the calculation of material removal rate (MRR) from the temperature isotherm. For MRR prediction, model uses a number of essential features viz. thermal properties of workpiece, shape and size of heat source (Gaussian heat distribution), material flushing efficiency, pulse off/on time, amount of heat division among the tool, dielectric fluid and workpiece etc. For developing the thermal model ANSYS software was used for the single spark simulation. In this investigation, Ti-5Al-2.5Sn titanium alloy and cylindrical copper was chosen as workpiece and electrode respectively. A comparative investigation has been performed considering the influence of process parameters viz. pulse on time, gap voltage, and peak current for experimental and theoretical MRR. Temperature distribution after material killing has been analyzed on the workpiece surface alongside the depth and radial direction. The model validation has been done by comparing the experimental MRR with the theoretical MRR and a good relationship has been found between them.
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