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A finite element based model for electrochemical discharge machining in discharge regime

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Abstract

Electrochemical discharge machining (ECDM) is a promising hybrid process for high-performance machining of non-conductive glass. ECDM drilling has been found to have different characteristics and material removal mechanisms in discharge regime (less than 300 μm in depth) and hydrodynamic regime (more than 300 μm in depth); however, these regimes are never separately modeled in existing ECDM models, which leads to large prediction error, especially at low applied voltages and high machining depths. Until now, no model is particularly designed for discharge regime, where most material is removed. In this paper, a finite element based model for ECDM drilling in discharge regime is presented. Material removal subjected to a single spark was simulated using finite element method. The drilling depth evolution in discharge regime was predicted. The model predictions were compared with experimental results for validation. The fraction of power transferred to workpiece was found to be about 29% in discharge regime.

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Authors and Affiliations

  1. School of Mechanical and Power Engineering, Shanghai Jiao Tong University, Shanghai, 200240, China

    Chenjun Wei, Kaizhou Xu & De** Hu

  2. Department of Mechanical Engineering, University of Michigan, Ann Arbor, 48109, MI, USA

    Jun Ni & Adam John Brzezinski

Authors
  1. Chenjun Wei
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  2. Kaizhou Xu
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  3. Jun Ni
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  4. Adam John Brzezinski
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  5. De** Hu
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Correspondence to Chenjun Wei.

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Wei, C., Xu, K., Ni, J. et al. A finite element based model for electrochemical discharge machining in discharge regime. Int J Adv Manuf Technol 54, 987–995 (2011). https://doi.org/10.1007/s00170-010-3000-0

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  • DOI: https://doi.org/10.1007/s00170-010-3000-0

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