FE Modelling of EDM Process

Abstract

An axisymmetric three dimensional model has been developed for temperature distribution in the electrical discharge machining process using the finite element method to estimate material removal rate (MRR), crater depth consisting of the studied features on which the effect of input process parameters like discharge current, discharge duration, discharge voltage on the performance measures like crater depth and MRR were investigated. The analysis has been carried out in ANSYS APDL 15.0. Both the numerical and experimental results show the same trends, there is increase in MRR with the increase in discharge voltage and discharge current. While there is first increase in MRR and then decrease in MRR with the increase in discharge duration. This is mainly due to the fact that on increasing the discharge duration the flux density decreases thus less MRR. EDM is a widely used manufacturing process used now days. It became very popular due to its wide usage and its advantages. In this process a spark is continuously produced between the gap provided between the anode and cathode. It is seen that the electrode which is connected to cathode gets eroded at a faster rate. the total current which is supplied to gets divided in parts one – third part goes to cathode and rest part goes to anode. Thus work piece is always connected to anode so that we can get higher material removal rate. This process became an indispensable process due to its uses in complex shape property.