Thermo-electrical coupling simulation of powder mixed EDM SiC/Al functionally graded materials

• Published in: International journal of advanced manufacturing technology Vol. 105; no. 5-6; pp. 2615 - 2628
• Main Authors: Tang, L., Ji, Y., Ren, L., Zhai, K. G., Huang, T. Q., Fan, Q. M., Zhang, J. J., Liu, J.
• Format: Journal Article
• Language: English
• Published: London Springer London 01.12.2019; Springer Nature B.V
• Subjects: CAE) and Design; Computer simulation; Computer-Aided Engineering (CAD; Coupling; Discharge; Electric discharge machining; Engineering; Functionally gradient materials; Industrial and Production Engineering; Material removal rate (machining); Mechanical Engineering; Media Management; Original Article; Pulse duration; Simulation; Surface properties; Surface roughness; Continuous multi-pulse discharge; Power mixed EDM; Surface roughness; Material removal rate; Thermo-electrical coupling simulation
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-019-04445-z

In order to solve the problem of low efficiency and poor surface quality, the method of powder mixed electrical discharge machining (PMEDM) was proposed for machining SiC/Al functionally graded materials (FGM). The thermo-electrical coupling simulation model was established. Based on the results of single-pulse discharge simulation, PMEDM material removal mechanism was researched. At the same time, the continuous multi-pulse EDM discharge dynamic simulation was studied. The position and the size of discharge crater and material removal rate (MRR) researched were discussed. Using PMEDM SiC/Al FGM, the crater depth is shallower and the radius is larger than traditional EDM. Under the condition of 5-wt% SiC/Al FGM, peak current 14 A, powder concentration 4 g/L, pulse width 175 μs, and pulse interval 75 μs, the maximum MRR error between simulation and experiment is 5.81%, and the minimum error is 4.13%. Compared with the traditional EDM, the efficiency of PMEDM is improved by 16.34%, and the surface roughness is reduced by 29.42%.