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

Date
2013
Authors
Hosseini Kalajahi, M.
Rash Ahmadi, S.
Nadimi Bavil Oliaei, S.
Advisor
Supervisor
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Instructor
Source Title
International Journal of Advanced Manufacturing Technology
Print ISSN
0268-3768
Electronic ISSN
Publisher
Volume
69
Issue
1-4
Pages
687 - 704
Language
English
Type
Article
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Journal ISSN
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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.

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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
Citation
Published Version (Please cite this version)