Thermal modelling of EDM process using FEA and parametric study of MRR

Abstract

Electric Discharge Machining (EDM) is highly suitable for machining of hard and tough conductive materials. The M2 grade of high-speed steel (HSS) is one of the tool material possess good thermal and mechanical properties. In the present study, a finite element analysis is done for conventional die-sinking EDM process and a model developed considering properties of M2 high-speed tool steel. The developed numerical model is simulated using ANSYS 15.0 for single spark. The transient thermal analysis of the 2D axisymmetric model is done considering temperature varying thermal and mechanical properties of the workpiece. The model results are used to study the effect of pulse-on time, duty cycle and discharge current on material removal rate. The experiments on M2 tool steel have been performed on an EDM machine to measure the material removal rate. The MRR obtained from the presented model are compared with the experimental results and numerical results are found quite compatible with the experimental results.