NDLI: Modeling of the Discharge-Sample Interaction in the Electron Discharge Machining (EDM) Process

Content Provider	IEEE Xplore Digital Library
Author	Revaz, B. Witz, G. Flukiger, R. Carron, J. Rappaz, M.
Copyright Year	2005
Description	Author affiliation: Dept. of Condensed Matter Phys., Geneva Univ. (Revaz, B.; Witz, G.; Flukiger, R.)
Abstract	Summary form only given. We present a global model of the discharge-sample interaction in the EDM environment. Using this model, important quantities that are of crucial importance for the development of EDM like the microstructure and the residual stress in the resolidified layer as well as the mass transfer controlling the erosion rate can be calculated accurately. A thermal model has been first elaborated on the basis of local temperature measurements made with a home made microthermocouple device and with a fast, high resolution IR CCD camera. These instruments allowed to determine experimentally the cathode plasma expansion rplasma(t) of a single discharge. This expansion is well described by a power law rplasmaproptn with n=0.2. The fraction of the discharge power transferred to the sample has been found to be 0.10 to be compared to 0.149 obtained in multiple spark experiment. Using this model, the thermal history of the resolidified layer (called white layer) is simulated and a multilayer structure is obtained in agreement with experimental observations. This multilayer is predicted to be composed of martensite and residual austenite. On the basis of this model, a stress analysis has been performed. This analysis demonstrates that the residual stress is due to a coupled effect of the martensite formation in the HAZ and the thermal history. This is in agreement with a model of crack formation in the white layer developed recently. The effect of multiple sparks has been simulated. The formation of continuous white and heat affected zone layers is obtained. This result accounts well for observations of the global EDM process. Finally, the same thermal model has been used to calculate numerically the convection flow in the melt pool created by the discharge. For the first time, it is shown that convection is important as early as 50 mus after the beginning of the spark. The role of the convection flow on the matter removal process will be discussed. These results open the route for novel applications of EDM for high quality surface treatment. Examples of these applications will be presented
Sponsorship	Plasma Sci. Appl. Comm. IEEE Nucl. Plasma Sci. Soc.
Starting Page	277
Ending Page	277
File Size	1177171
Page Count	1
File Format	PDF
ISBN	0780393007
ISSN	07309244
DOI	10.1109/PLASMA.2005.359371
Language	English
Publisher	Institute of Electrical and Electronics Engineers, Inc. (IEEE)
Publisher Date	2005-06-20
Publisher Place	USA
Access Restriction	Subscribed
Rights Holder	Institute of Electrical and Electronics Engineers, Inc. (IEEE)
Subject Keyword	Electrons Machining Residual stresses Sparks History Nonhomogeneous media Thermal stresses Microstructure Weight control Stress control
Content Type	Text
Resource Type	Article
Subject	Atomic and Molecular Physics, and Optics Condensed Matter Physics Electrical and Electronic Engineering

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