Finite Element based Numerical Modelling of Near-Dry EDM with Glycerin-Air Dielectric Mixture

Abstract

Electrical discharge machining (EDM) is an advanced, non-traditional machining process that is widely employed in sectors such as manufacturing, automotive, aerospace, and medicine. Near-dry EDM is a prospective technology that offers advantages over dry and wet EDM in terms of material removal rate (MRR), tool wear rate (TWR), and surface integrity. A 2D model of the axi-symmetric workpiece based on the Gaussian distribution of the heat flux is used to simulate the single spark in near-dry EDM. The MRR of near-dry EDM is determined at various glycerin flow rates in the glycerin-air combination. The simulation is then performed on the SS304 workpiece with different glycerin flow rates. The results are compared to EDM simulations using N 2 and O 2 as the dielectric medium. The average MRR of near-dry EDM with an 8 ml/min glycerin flow rate is determined to be 204% higher than that of N2 and 117% higher than that of O 2 gas dielectric. When the volumetric ratio of glycerin in the glycerin-air combination increases, the MRR was also found to be increasing. The maximal MRR of near-dry EDM was found to be 129.30703 mm 3 /min with an 8 ml/min glycerin flow rate and a 0.18 volumetric ratio and a maximal MRR of 144.3407 mm 3 /min was found with a 15 ml/min glycerin flow rate and a 0.35 volumetric ratio.