Comparative experimental investigation and gap flow simulation in electrical discharge drilling using new electrode geometry

This study presents experimental and numerical investigation on the effectiveness of electrode geometry on flushing and debris removal in Electrical Discharge Drilling (EDD) process. A new electrode geometry, namely side-cut electrode, was designed and manufactured based on circular electrode geomet...

Full description

Saved in:
Bibliographic Details
Published inMechanical sciences (Göttingen) Vol. 8; no. 2; pp. 289 - 298
Main Authors Bozdana, Ali Tolga, Al-Karkhi, Nazar Kais
Format Journal Article
LanguageEnglish
Published Gottingen Copernicus GmbH 20.09.2017
Copernicus Publications
Subjects
Analysis
Austenitic stainless steels
Bubbles
CAD
Comparative analysis
Computational fluid dynamics
Computer aided design
Computer simulation
Drilling
Electric discharges
Electric metal cutting
Electrodes
Electrons
Erosion
Erosion rates
Flow simulation
Flushing
Geometry
Material removal rate (machining)
Mathematical models
Rapid prototyping
Reynolds number
Stainless steel
Surface properties
Surface roughness
Technology application
Three dimensional models
Tool steels
Tool wear
Wear rate
Online AccessGet full text

Cover

More Information
Summary:This study presents experimental and numerical investigation on the effectiveness of electrode geometry on flushing and debris removal in Electrical Discharge Drilling (EDD) process. A new electrode geometry, namely side-cut electrode, was designed and manufactured based on circular electrode geometry. Several drilling operations were performed on stainless steel 304 using rotary tubular electrodes with circular and side-cut geometries. Drilling performance was characterized by Material Removal Rate (MRR), Electrode Wear Rate (EWR), and Tool Wear Ratio (TWR). Dimensional features and surface quality of drilled holes were evaluated based on Overcut (OC), Hole Depth (HD), and Surface Roughness (SR). Three-dimensional three-phase CFD models were built using ANSYS FLUENT software to simulate the flow field at interelectrode gap. Results revealed that the overall performance of side-cut electrode was superior due to improved erosion rates and flushing capabilities, resulting in production of deep holes with good dimensional accuracy and surface quality.
ISSN:2191-916X
2191-9151
2191-916X
DOI:10.5194/ms-8-289-2017