Single discharge thermo-electrical modeling of micromachining mechanism in electric discharge machining

Sarikavak, Yasin
Cogun, Can
In this study, single discharge thermo-electrical model of workpiece material removal in electrical discharge machining (EDM) was developed. Developed model includes generation of energy in liquid media, variation of plasma channel radius and transfer of heat from the channel by the electrical discharge. Effect of generated energy in plasma channel on workpiece removal was theoretically investigated by using different experimental parameters used in literature. The developed model finds the temperature distribution in the workpiece material using finite element solver ANSYS Workbench (v.11) software. It's assumed that the workpiece material reaches the melting point of workpiece material was removed from the surface. Electrical discharge process was simulated by using transient thermal analysis. The developed model has also been validated by comparing the theoretically obtained material removal values with the experimental ones.


Cogun, Can; Deniz, Tayfun Caglar; Kucukturk, Gokhan (2012-01-01)
In this study, the geometric wear characteristics of tool electrodes were obtained for various pulse time, discharge current and machining depth settings in electric discharge machining. Different forms of protrusions were machined on the front surface of the tool to reduce the geometric wear. Significant reductions in original tool geometric wear characteristics (front wear, side wear and edge wear) were obtained with the use of square cross-section protrusions. The dimensions of the square cross-section p...
Theoretical and experimental investigation of residual stresses in electric discharge machining
Ekmekçi, Bülent; Erden, Abdülkadir; Department of Mechanical Engineering (2004)
Electric Discharge Machining (EDM) is a process for eroding and removing material by transient action of electric sparks on electrically conductive materials immersed in a dielectric liquid and separated by a small gap. A spark-eroded surface is a surface with matt appearance and random distribution of overlapping craters. It is mechanically hard and stressed close to ultimate tensile strength of the material and sometimes covered with a network of micro cracks. The violent nature of the process leads a uni...
Micro processing by intense fast electron beam
Goktas, H; Kirkici, H; Oke, G; Udrea, M (2001-06-22)
Generation of intense electron beams by superposing two discharges, namely a low pressure do glow discharge and a high current pulsed discharge at pressures and voltages very similar to that of the pseudo-spark gap devices, has been reported previously [1, 2]. The small diameter, high peak current and short pulse length are the characteristics of the electron beam generated using this technique. In this technique, no high vacuum facilities are necessary, and many applications such as micro processing, X-ray...
Single axis precise motion control using piezoactuator associated with a compliant mechanism
Yaşar, Gökhan; Balkan, Raif Tuna; Yaman, Yavuz; Department of Mechanical Engineering (2013)
Mechanical amplification is achieved using a multi-flexure-hinge based compliant mechanism, due to limited displacement range of piezoactuator. In the design stage of mechanism, a comparison matrix analysis is performed to decide the best alternative among the possible compliant mechanism candidates. The mechanical design parameters of the displacement amplifier is determined optimally using the analytical equation derived using Pseudo Rigid Body Model, and the static analysis is performed using finite elem...
An investigation on sample size distribution in electric discharge machining (EDM)
Darendeliler, Haluk (1991-01-01)
In this study, 150 experiments are conducted at different machining conditions to determine the sample size for workpiece removal rate and tool wear rate with a certain acceptable error in Electric Discharge Machining (EDM). Experimental workpiece removal rate and tool wear rate data are found to be distributed normally with a good fit. Statistically, it is shown that 150 experiments are large enough random sample to reflect the characteristics of the population. Two methods are proposed to find the sample ...
Citation Formats
Y. Sarikavak and C. Cogun, “Single discharge thermo-electrical modeling of micromachining mechanism in electric discharge machining,” JOURNAL OF MECHANICAL SCIENCE AND TECHNOLOGY, pp. 1591–1597, 2012, Accessed: 00, 2020. [Online]. Available: