Abstract
The high temperature distribution generated during electro-chemical spark machining (ECSM) results in large localised thermal stresses in a very small heat affected zone. These thermal stresses can lead to micro-cracks and a decrease in strength and fatigue life of the components. A finite element model is developed to estimate the temperature distribution and thermal stresses due to a single spark (Gaussian distributed heat flux) and within the zone of influence of a single spark. Firstly, the finite element based (FEM) code is developed to estimate temperature distribution in the workpiece due to a single spark and, based on this temperature distribution, thermal stresses are calculated. Thermal stress analysis shows high temperature gradient zones and the regions of large stresses where, sometimes, they exceed the material yield strength.
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