Abstract
Several modeling and simulations have been reported to characterize the electric discharge machining (EDM) and micro-electric discharge machining (micro-EDM) processes. However, these models have been considered spark radius as a function of time or time and current as well as these models are valid only for transistor-type pulse discharge circuits. Therefore, it is important to develop an accurate model to predict the spark radius for RC-relaxation circuits where capacitance and voltage are the important process parameters. In this paper, an attempt has been made to develop a mathematical model predicting the single-spark radius produced during micro-EDM of Ti-6Al-4V. A series of experiments were conducted based on three-level full factorial experimental design with four center point runs. Capacitance and voltage were taken as the variable factors and spark radius was measured as the response. Based on the experimental results, the effect of capacitance and voltage on spark radius was studied in detail with analysis of variance. The results showed that capacitance significantly influenced the spark radius compared to voltage. In addition, a mathematical model has been developed to correlate the capacitance and voltage with spark radius by adopting regression analysis. Finally, the developed model equation was validated with confirmatory experiments and the predicted and experimental spark radius was found to be in good agreement with a prediction error less than 5 %.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Jahan MP, Rahman M, Wong YS (2011) A review on the conventional and micro electric discharge machining of tungsten carbide. Int J Mach Tools Manuf 51:837–858
Kuriachen B, Somashekhar KP, Mathew J (2014) Multiresponse optimization of micro-wire electrical discharge machining process. Int J Adv Manuf Technol. doi:10.1007/s00170-014-6005-2
Jilani ST, Pandey PC (1982) Analysis and modeling of EDM parameters. Precis Eng 4:215–221
Dibitonto DD, Eubank PT, Patel MR, Barrufet MA (1989) Theoretical model of the electric discharge machining process. I. The cathode erosion model. J Appl Phys 66:4095–4103
Patel MR, Barrufet MA, Eubank PT, Dibitonto DD (1989) Theoretical model of the electric discharge machining process. II. The anode erosion model. J Appl Phys 66:4104–4111
Shankar P, Jain VK, Sundararajan T (1997) Analysis of spark profiles during EDM process. Mach Sci Technol 1:195–217
Ajit S, Amitabha G (1999) A thermo electric model of material removing during electric discharge machining. Int J Mach Tools Manuf 39:669–682
Yu ZY, Kozak J, Rajurkar KP (2003) Modeling and simulation of micro EDM process. CIRP Ann 52:143–146
Dhanik S, Joshi SS (2005) Modeling of a single resistance capacitance pulse discharge in micro electro discharge machining. J Manuf Sci Eng 127:759–767
Marafona J, Chousal JAG (2006) A finite element model of EDM based on the joule effect. Int J Mach Tools Manuf 46:595–602
Joshi SN, Pande SS (2009) Development of an intelligent process model for EDM. Int J Adv Manuf Technol 45:300–317
Izquierdo B, Sanchez JA, Plaza S, Pombo I, Ortega N (2009) A numerical model of the EDM process considering the effect of multiple discharges. Int J Mach Tools Manuf 49:220–229
Joshi SN, Pande SS (2010) Thermo physical modeling of die sinking EDM process. J Manuf Process 12:45–56
Xie BC, Wang YK, Wang ZL, Zhao WS (2011) Numerical simulation of titanium alloy machining in electric discharge machining process. Trans Nonferrous Metals Soc China 21:434–439
Shabgard M, Ahmadi R, Seyedzavvar M, Oliaei SNB (2013) Mathematical and numerical modeling of the effect of input-parameters on the flushing efficiency of plasma channel in EDM process. Int J Mach Tools Manuf 65:79–87
Izquierdo B, Plaza S, Sanchez JA, Pombo I, Ortega N (2012) Numerical prediction of heat affected layer in the EDM of aeronautical alloys. Appl Surf Sci 259:780–790
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
Yeo SH, Kurnia W, Tan PC (2008) Critical assessment and numerical comparison of electro thermal models in EDM. J Mater Process Technol 203:241–251
Snoeys R, Van Dijick FS (1971) Investigation of electro discharge machining operations by means of thermo mathematical model. CIRP Ann 20:35–37
Van Dijick FS, Dutre WL (1974) Heat conduction model for the calculation of the volume of molten metal in electric discharges [discharge machining]. J Phys D (Appl Phys) 7:899–910
Beck JV (1981) Transient temperatures in a semi-infinite cylinder heated by a disk heat source. Int J Heat Mass Transf 24:1631–1640
Jilani ST, Pandey PC (1983) Analysis of surface erosion in electrical discharge machining. Wear 84:275–284
Dhanik S, Joshi SS, Ramakrishnan N, Apte PR (2005) Evolution of EDM process modeling and development towards modeling of the micro EDM process. Int J Manuf Technol Manag 7:157–180
Yu ZY, Kozak J, Rajurkar KP (2003) Modeling and simulation of micro EDM process. CIRP Ann Manuf Technol 52:143–146
Murali MS, Yeo SH (2005) Process simulation and residual stress estimation of micro electric discharge machining using finite element method. J Appl Phys 44(7A):5254–5263
Yeo SH, Kurnia W, Tan PC (2007) Electro thermal modeling of anode and cathode in micro EDM. J Phys D 40(8):2513
Kiran KMP, Joshi SS (2007) Modeling of surface roughness and the role of debris in micro-EDM. J Manuf Sci Eng 129(2):265–273
Allen P, Chen X (2007) Process simulation of micro electro discharge machining on molybdenum. J Mater Process Technol 186:346–355
Mathew J, Allesu K, Srisailam S, Somashekar KP, Prakash Naidu P, Suvin PS (2012) Estimation of residual stress and crater shape in μ-EDM by finite element method. Proceedings of 7th ASME International conference, Texas, USA
Somashekhar KP, Mathew J, Ramachandran N (2012) Electrothermal theory approach for numerical approximation of the μ-EDM process. Int J Adv Manuf Technol 61:1241–1246
Somashekhar KP, Panda S, Mathew J, Ramachandran N (2013) Numerical simulation of micro-EDM model with multi-spark. Int J Adv Manuf Technol. doi:10.1007/s00170-013-5319-9
Tan PC, Yeo SH (2008) Modeling of overlapping craters on micro-electrical discharge machining. J Phys D 41(20):205302
Karthikeyan G, Garga AK, Ramkumar J, Dhamodaran S (2012) A microscopic investigation of machining behavior in ED-milling process. J Manuf Process 14:297–306
Yoo BH, Min BK, Lee SJ (2010) Analysis of the machining characteristics of EDM as functions of the mobilities of electrons and ions. Int J Precis Eng Manuf 11(4):629–632
Jahan MP, Wong YS, Rahman M (2010) A study on the quality micro-hole machining of tungsten carbide by micro-EDM process using transistor and RC-type pulse generator. J Mater Process Technol 209:1706–1716
Luo UF (1995) The dependence of interspace discharge transitivity upon the gap debris in precision electrodischarge machining. J Mater Process Technol 68(2):121–131
Chen Y, Mahdivian SM (2000) Analysis of electro-discharge machining process and its comparison with experiments. J Mater Process Technol 104(1–2):150–157
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Kuriachen, B., Mathew, J. Spark radius modeling of resistance-capacitance pulse discharge in micro-electric discharge machining of Ti-6Al-4V: an experimental study. Int J Adv Manuf Technol 85, 1983–1993 (2016). https://doi.org/10.1007/s00170-015-7999-9
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-015-7999-9