Abstract
In electrical discharge machining (EDM), material is heated to an extremely high temperature then moved by melting and vaporization. Understanding the energy distribution and heat transfer during the process is conducive to knowing more about the machining mechanism of EDM. Many researches have been conducted to explore the energy distribution in micro EDM. Almost all of these efforts did not consider the difference in material removal mechanism between conventional and micro EDM, which has severe effects on the accuracy of their research. This paper proposes a method in regard to micro EDM for estimating plasma radius and energy distribution through comparing the results of experiment and theoretical calculation. In this method, the differences in the material removal mechanism between conventional and micro EDM are properly considered. The results of single discharge experiment were analyzed by this method. The plasma radius and fraction of energy transferred into workpiece are determined by the discharge current and discharge duration. The increase of discharge current and discharge duration led to the increase of plasma radius, while low discharge current and high discharge duration is helpful for improving the fraction of energy transferred into workpiece.
Similar content being viewed by others
References
Moses M-D, Jahan MP (2015) Micro-EDM machinability of difficult-to-cut Ti-6Al-4V against soft brass. Int J Adv Manuf Technol 81(5–8):1345–1361. doi:10.1007/s00170-015-7306-9
Essa K, Modica F, Imbaby M, El-Sayed MA, ElShaer A, Jiang K, Hassanin H (2016) Manufacturing of metallic micro-components using hybrid soft lithography and micro-electrical discharge machining. Int J Adv Manuf Technol. doi:10.1007/s00170-016-9655-4
Xu B, Wu X-y, J-g L, Cheng R, S-c R, Wang Z-l (2015) Laminated fabrication of 3D queue micro-electrode and its application in micro-EDM. Int J Adv Manuf Technol 80(9–12):1701–1711. doi:10.1007/s00170-015-7148-5
Hourmand M, Sarhan AAD, Sayuti M (2016) Micro-electrode fabrication processes for micro-EDM drilling and milling: a state-of-the-art review. Int J Adv Manuf Technol. doi:10.1007/s00170-016-9671-4
DiBitonto DD, Eubank PT, Patel MR, Barrufet MA (1989) Theoretical models of the electrical discharge machining process. I. A simple cathode erosion model. J Appl Phys 66(9):4095. doi:10.1063/1.343994
Yeo SH, Kurnia W, Tan PC (2007) Electro-thermal modelling of anode and cathode in micro-EDM. J Phys D Appl Phys 40(8):2513–2521. doi:10.1088/0022-3727/40/8/015
Bigot S, D’Urso G, Pernot J-P, Merla C, Surleraux A (2016) Estimating the energy repartition in micro electrical discharge machining. Precis Eng 43:479–485. doi:10.1016/j.precisioneng.2015.09.015
Singh H (2012) Experimental study of distribution of energy during EDM process for utilization in thermal models. Int J Heat Mass Transf 55(19):5053–5064
Zahiruddin M, Kunieda M (2012) Comparison of energy and removal efficiencies between micro and macro EDM. CIRP Ann Manuf Technol 61(1):187–190. doi:10.1016/j.cirp.2012.03.006
Shen Y, Liu Y, Zhang Y, Tan B, Ji R, Cai B, Zheng C (2013) Determining the energy distribution during electric discharge machining of Ti–6Al–4V. Int J Adv Manuf Technol 70(1–4):11–17. doi:10.1007/s00170-013-5194-4
Zhang Y, Liu Y, Shen Y, Li Z, Ji R, Cai B (2014) A novel method of determining energy distribution and plasma diameter of EDM. Int J Heat Mass Transf 75:425–432. doi:10.1016/j.ijheatmasstransfer.2014.03.082
Shao B Rajurkar KP micro-EDM pulse energy distribution ratio determination. In: International Conference on MicroManufacturing, 2013
Hoang KT, Gopalan SK, Yang S-H (2015) Study of energy distribution to electrodes in a micro-EDM process by utilizing the electro-thermal model of single discharges. J Mech Sci Technol 29(1):349–356. doi:10.1007/s12206-014-1241-9
Wang K, Zhang Q, Liu Q, Zhu G, Zhang J (2017) Experimental study on micro electrical discharge machining of porous stainless steel. Int J Adv Manuf Technol 90(9–12):2589–2595. doi:10.1007/s00170-016-9611-3
Liu Q, Zhang Q, Zhang M, Zhang J (2014) Effect of crystallographic anisotropy on micro EDM process. Mater Manuf Process 30(8):961–967. doi:10.1080/10426914.2014.962660
Bor-Jenq W, Nannaji S, Ernest R (1992) Static-gap, single-spark erosion of Ag-CdO and pure metal electrodes. Wear 157(1):31–49
Zahiruddin M, Kunieda M (2010) Energy distribution ratio into micro EDM electrodes. J Adv Mech Des Syst Manuf 4(6):1095–1106
Liu Q, Zhang Q, Zhang M, Zhang J (2016) Review of size effects in micro electrical discharge machining. Precis Eng 44:29–40. doi:10.1016/j.precisioneng.2016.01.006
Shabgard M, Akhbari S (2016) An inverse heat conduction method to determine the energy transferred to the workpiece in EDM process. Int J Adv Manuf Technol 83(5–8):1037–1045
Somashekhar KP, Panda S, Mathew J, Ramachandran N (2013) Numerical simulation of micro-EDM model with multi-spark. Int J Adv Manuf Technol 76(1–4):83–90. doi:10.1007/s00170-013-5319-9
Jilani ST, Pandey P (1982) Analysis and modelling of EDM parameters. Precis Eng 4(4):215–221
Carslaw HS, Jaeger JC (1959) Conduction of heat in solids. Oxford: Clarendon Press, 1959, 2nd ed
Thomas P (1957) Some conduction problems in the heating of small areas on large solids. Q J Mech Appl Math 10(4):482–493
Beck JV (1981) Large time solutions for temperatures in a semi-infinite body with a disk heat source. Int J Heat Mass Transf 24(1):155–164. doi:10.1016/0017-9310(81)90104-6
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Wang, K., Zhang, Q., Zhu, G. et al. Research on the energy distribution of micro EDM by utilization of electro-thermal model. Int J Adv Manuf Technol 93, 4179–4186 (2017). https://doi.org/10.1007/s00170-017-0822-z
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-017-0822-z