Mathematical modelling of MRR and Heat flux using FEA in the ECDM process
Keywords:
Electrochemical discharge machining, Finite element analysis, Material removal rate, Gaussian heat generation, Heat affected zone.Abstract
Electrochemical discharge machining (ECDM) is a non-conventional technology which is mostly applied for the effective and economical micro- machining of several non-conductive materials. Most of the application of ECDM is in machining nonconductive materials, although some authors have also tried machining conductive materials. This paper attempts to mathematical modelling for MRR and develop a Finite element simulation model based on heat generation in spark region to evaluate material removal rate (MRR) of quartz material. The first one is the development of a thermal finite element model to estimate the temperature distribution within the heat-affected zone (HAZ) of series of spark on the workpiece. In ECDM the heating from the spark zone is considered as a Gaussian distribution on the surface of the workpiece. The calculation of MRR is based on melting and evaporation of the material due to high temperature of the spark.
