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      • Department of Mechanical Engineering
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      Experimental and finite element analysis of EDM process and investigation of material removal rate by response surface methodology

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      Author
      Hosseini Kalajahi, M.
      Rash Ahmadi, S.
      Nadimi Bavil Oliaei, S.
      Date
      2013
      Source Title
      International Journal of Advanced Manufacturing Technology
      Print ISSN
      0268-3768
      Volume
      69
      Issue
      1-4
      Pages
      687 - 704
      Language
      English
      Type
      Article
      Item Usage Stats
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      Abstract
      In this study, thermal modeling and finite element simulation of electrical discharge machining (EDM) has been done, taking into account several important aspects such as temperature-dependent material properties, shape and size of the heated zone (Gaussian heat distribution), energy distribution factor, plasma flushing efficiency, and phase change to predict thermal behavior and material removal mechanism in EDM process. Temperature distribution on the cathode has been calculated using ANSYS finite element code, and the effect of EDM parameters on heat distribution along the radius and depth of the workpiece has been obtained. Temperature profiles have been used to calculate theoretical material removal rate (MRR) from the cathode. Theoretically calculated MRRs are compared with the experimental results, making it possible to precisely determine the portion of energy that enters the cathode for AISI H13 tool steel. Also in this paper, the effect of EDM parameters on MRR has been investigated by using the technique of design of experiments and response surface methodology. Finally, a quadratic polynomial regression model has been proposed for MRR, and the accuracy of this model has been checked by means of analysis of residuals. © 2013 Springer-Verlag London.
      Keywords
      DOE
      EDM
      FEM
      MRR
      RSM
      DOE
      EDM
      Electrical discharge machining
      Gaussian heat distributions
      MRR
      Response surface methodology
      RSM
      Temperature-dependent material properties
      Cathodes
      Design of experiments
      Electric properties
      Regression analysis
      Surface properties
      Tool steel
      Finite element method
      Permalink
      http://hdl.handle.net/11693/20957
      Published Version (Please cite this version)
      http://dx.doi.org/10.1007/s00170-013-5059-x
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