Study on the Gap Flow Simulation in EDM Small Hole Machining with Ti Alloy
In electrical discharge machining (EDM) process, the debris removed from electrode material strongly affects the machining efficiency and accuracy, especially for the deep small hole machining process. In case of Ti alloy, the debris movement and removal process in gap flow between electrodes for sm...
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| Main Authors: | , , , , , |
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| Format: | Article |
| Language: | English |
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Wiley
2017-01-01
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| Series: | Advances in Materials Science and Engineering |
| Online Access: | http://dx.doi.org/10.1155/2017/8408793 |
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| author | Shengfang Zhang Wenchao Zhang Yu Liu Fujian Ma Chong Su Zhihua Sha |
| author_facet | Shengfang Zhang Wenchao Zhang Yu Liu Fujian Ma Chong Su Zhihua Sha |
| author_sort | Shengfang Zhang |
| collection | DOAJ |
| description | In electrical discharge machining (EDM) process, the debris removed from electrode material strongly affects the machining efficiency and accuracy, especially for the deep small hole machining process. In case of Ti alloy, the debris movement and removal process in gap flow between electrodes for small hole EDM process is studied in this paper. Based on the solid-liquid two-phase flow equation, the mathematical model on the gap flow field with flushing and self-adaptive disturbation is developed. In our 3D simulation process, the count of debris increases with number of EDM discharge cycles, and the disturbation generated by the movement of self-adaptive tool in the gap flow is considered. The methods of smoothing and remeshing are also applied in the modeling process to enable a movable tool. Under different depth, flushing velocity, and tool diameter, the distribution of velocity field, pressure field of gap flow, and debris movement are analyzed. The statistical study of debris distribution under different machining conditions is also carried out. Finally, a series of experiments are conducted on a self-made machine to verify the 3D simulation model. The experiment results show the burn mark at hole bottom and the tapered wall, which corresponds well with the simulating conclusion. |
| format | Article |
| id | doaj-art-34e23e5062c64bc899cb94c7cf132b33 |
| institution | Kabale University |
| issn | 1687-8434 1687-8442 |
| language | English |
| publishDate | 2017-01-01 |
| publisher | Wiley |
| record_format | Article |
| series | Advances in Materials Science and Engineering |
| spelling | doaj-art-34e23e5062c64bc899cb94c7cf132b332025-02-03T01:31:10ZengWileyAdvances in Materials Science and Engineering1687-84341687-84422017-01-01201710.1155/2017/84087938408793Study on the Gap Flow Simulation in EDM Small Hole Machining with Ti AlloyShengfang Zhang0Wenchao Zhang1Yu Liu2Fujian Ma3Chong Su4Zhihua Sha5School of Mechanical Engineering, Dalian Jiaotong University, Dalian 116028, ChinaSchool of Mechanical Engineering, Dalian Jiaotong University, Dalian 116028, ChinaSchool of Mechanical Engineering, Dalian Jiaotong University, Dalian 116028, ChinaSchool of Mechanical Engineering, Dalian Jiaotong University, Dalian 116028, ChinaSchool of Mechanical Engineering, Dalian Jiaotong University, Dalian 116028, ChinaSchool of Mechanical Engineering, Dalian Jiaotong University, Dalian 116028, ChinaIn electrical discharge machining (EDM) process, the debris removed from electrode material strongly affects the machining efficiency and accuracy, especially for the deep small hole machining process. In case of Ti alloy, the debris movement and removal process in gap flow between electrodes for small hole EDM process is studied in this paper. Based on the solid-liquid two-phase flow equation, the mathematical model on the gap flow field with flushing and self-adaptive disturbation is developed. In our 3D simulation process, the count of debris increases with number of EDM discharge cycles, and the disturbation generated by the movement of self-adaptive tool in the gap flow is considered. The methods of smoothing and remeshing are also applied in the modeling process to enable a movable tool. Under different depth, flushing velocity, and tool diameter, the distribution of velocity field, pressure field of gap flow, and debris movement are analyzed. The statistical study of debris distribution under different machining conditions is also carried out. Finally, a series of experiments are conducted on a self-made machine to verify the 3D simulation model. The experiment results show the burn mark at hole bottom and the tapered wall, which corresponds well with the simulating conclusion.http://dx.doi.org/10.1155/2017/8408793 |
| spellingShingle | Shengfang Zhang Wenchao Zhang Yu Liu Fujian Ma Chong Su Zhihua Sha Study on the Gap Flow Simulation in EDM Small Hole Machining with Ti Alloy Advances in Materials Science and Engineering |
| title | Study on the Gap Flow Simulation in EDM Small Hole Machining with Ti Alloy |
| title_full | Study on the Gap Flow Simulation in EDM Small Hole Machining with Ti Alloy |
| title_fullStr | Study on the Gap Flow Simulation in EDM Small Hole Machining with Ti Alloy |
| title_full_unstemmed | Study on the Gap Flow Simulation in EDM Small Hole Machining with Ti Alloy |
| title_short | Study on the Gap Flow Simulation in EDM Small Hole Machining with Ti Alloy |
| title_sort | study on the gap flow simulation in edm small hole machining with ti alloy |
| url | http://dx.doi.org/10.1155/2017/8408793 |
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