ACTA

On the Use of Deformed Geometry in EDM Modelling: Comparative Study

E.L. Papazoglou^a, P. Karmiris-Obratański^{a, b}, N.E. Karkalos^a, A.P. Markopoulos^a
^aNational Technical University of Athens, School of Mechanical Engineering, Laboratory of Manufacturing Technology, Heroon Polytechniou 9, 15780, Athens, Greece
^bAGH University of Science and Technology, Faculty of Mechanical Engineering and Robotics, Department of Manufacturing Systems, al. Mickiewicza 30, 30059 Cracow, Poland

Full Text PDF

Electrical Discharge Machining (EDM) is one of the earliest non-conventional machining processes, which still finds extensive application in modern industry. It is a non-contact process, with capability to handle any conductive material, regardless of other properties, like its strength and hardness. In EDM, the material is removed by repetitive sparks, which melt and ablate material from the machined surface. In this way, high dimensional accuracy can be achieved along with the creation of complex shapes and geometries. There are many machining parameters that affect the process, which have a nonlinear effect to the final machining result. Thus, modelling and simulation of the process provide an advantage on understanding the undergoing physical phenomena, and the subsequent optimization of the process. Nevertheless, there are many aspects that have to be taken into consideration, in order for realistic and accurate results to emerge from simulations. The most common method of modelling the EDM is by simulating a single spark caused by plasma channel. One crucial parameter is the use of a deforming geometry with moving mesh, to simulate the heat transfer and the simultaneous material removal. The current paper presents a comparative study of EDM modelling and simulation, between a constant mesh model and a moving mesh one. Heat transfer models are solved, with same thermal boundary conditions, but they differ in the use of a constant or a moving mesh.

DOI:10.12693/APhysPolA.138.268
topics: Electrical Discharge Machining, modeling and simulation, moving mesh