Finite element modelling of Electric Discharge Machining Process

Electric Discharge Machining is one of the most popular, efficient and accurate machining processes. The major aim of the project is the thermal modeling of EDM sparks. Thermal modeling of EDM has been undertaken quite a few times in past decades and literature presents various arguments to its formulation. However, many previous models significantly over predict the process performance possibly due to the simplifying assumptions, hence; there is a need to develop a more accurate and realistic thermophysical numerical model for EDM by analyzing the spark phenomenon and mechanism of material removal in EDM. The present project aims to present a numerical model for predicting temperature distribution over workpiece surface due to single and multiple EDM sparks, with realistic characterization of boundary conditions, other factors behind the actual conditions governing the process. The Material Removal Rate (MRR) has also been calculated using the results for the above case. Parametric studies are performed on multiple sparks model with and without material erosion to understand the influence of various input process parameters on the performance measures such as crater depth and MRR.