Experimental and numerical investigations of material removal process in electrochemical discharge machining of glass in discharge regime |
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| Affiliation: | 1. Electrochemical Microfabrication Laboratory, Department of Mechanical Engineering, Indian Institute of Technology Bombay, Mumbai, 400076, India;2. Advanced Manufacturing Processes Laboratory, Department of Mechanical and Industrial Engineering, Indian Institute of Technology Roorkee, Roorkee, 247667, India;1. Department of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109, USA;2. School of Mechanical Engineering, Jiangsu University, Zhenjiang, Jiangsu 212013, China;1. National NC System Engineering Research Center, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China;2. Department of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109, USA |
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| Abstract: | Electrochemical discharge machining (ECDM) can be applied as a non-traditional processing technology for machining non-conductive materials such as glass and ceramics, based on the phenomena of evoked electrochemical discharges around the tool electrode. The material removal mechanism of ECDM is noticeably complex and difficult to experimentally characterize. In this paper, finite element models were proposed to predict the material removal in the ECDM discharge regime. First, the single-pulse discharge on a tapered electrode was modeled. It was found that about 30.5% of the discharge energy is transferred to the workpiece. The continuous discharge on a cylindrical electrode was thereafter modeled according to this phenomenon, in which the removal of a layer of the workpiece material starts from the projected contour of the edge of the electrode end and extends inward during the ECDM processing. The effective discharge ratio for material removal was calculated to be 10.1%. The drilling depths of holes at different applied voltages were predicted by the proposed finite element method. It was found that the predicted values were consistent with the experimental results. |
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| Keywords: | Electrochemical discharge machining (ECDM) Material removal mechanism Finite element model (FEM) Process modeling |
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