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Simulation of Die-Sinking EDM by Discharge Location Searching Algorithm
Simulation of Die-Sinking EDM by Discharge Location Searching Algorithm
3, January 1998
Abstract
This paper deals with simulation of workpiece geometry eroded by a die-sinking EDM using a newly
developed simulation algorithm for faithful imitation of the actual phenomena which are occurring in the gap.
The algorithm is a simple repetition of the procedure which is comprised of: (1) determining the next
discharge location where the dielectric breakdown strength is lowest, (2) removing the tool and workpiece
electrodes, (3) distributing the debris particles, and (4) feeding the tool electrode. The simulation takes into
account a variety of influential factors such as tool electrode wear, gap width distribution, curvature and
inclination of the tool electrode, and debris particle concentration, all of which affect each other in a very
complex manner. The simulation results for the geometries of the tool electrode and the workpiece after
machining and for the gap width distribution agree well with the experimental results for machining of a flat
and square surface.
Key words: die sinking EDM, simulation, machining accuracy, tool electrode wear, discharge gap, debris
particles
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Removal of tool electrode
per single pulse discharge
Debris
Gap
Removal of workpiece
per single pulse discharge
a) Gap model
· h t Debris particles
D ISC arge spo
which describes the procedure of identifying the between the thickness of the deposited layer and
next discharge location based on an index defined electrode wear has not yet been obtained.
so that its value correlates with the probability of
discharge breakdown. Our method takes into 2. OUTLINE OF SIMULATION
account all of the relations indicated by *) in Fig.
1. However, we ignore the influence of the 2.1 Algorithm
deposition of the electrode materials12) and In the actual EDM process, the discharge is
carbon 13)-16) over the tool electrode surface on tool intermittent and there is only one discharge
electrode wear, because the quantitative relation location for each pulse discharge. The discharge
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location is determined by the dielectric breakdown section at which the index of discharge probability
strength of the gap, which is influenced by the gap described below is highest. Figure 4 shows the
width and the concentration of debris particles. relation between the gap width and the debris
The developed simulation algorithm shown in Fig. particle concentration which was obtained by
2 describes the phenomena occurring in the Kunieda and Moril1). Here the debris particle
working gap and is composed of the following concentration at the mesh section is defined as the
steps. volume fraction of debris particles in the gap
First, over the working surface of the tool region whose volume is expressed as the product
electrode, which has been formed of mesh, we of the mesh area and the gap width. With respect
search for the mesh point at which the index of to the calculated debris particle concentration, we
discharge probability, which will be described later, can obtain the equilibrium gap from Fig. 4, which
is highest. Considering the gap width and the is the normal gap to be maintained in the steady
curvature at the mesh, we calculate the depth of state at the constant feed rate of the tool electrode.
the layer removed from the tool electrode and the Here, subtraction of the current gap width from the
workpiece based on the data obtained equilibrium gap gives the index of discharge
experimentally. Then, as shown in Fig. 3(a), the probability at the mesh section.
coordinate of the section of mesh is displaced by On a flat surface of the tool electrode, the
the distance equal to the calculated depth of the electric field is given by:
layer removed in the direction normal to the
surface. In the third step, newly generated debris (1)
particles are placed around the discharge spot (Fig.
3(b)), and all the existing debris particles are where u j is the open voltage and hflol is the gap
relocated corresponding to the rapid expansion of width. At a vertex whose radius of curvature is r,
a bubble which is composed of the vapor and the the electric field on the surface can be
dissociated gases of the dielectric liquid. In the approximated by that between two concentric
last step, the tool electrode is fed and the resultant spherical surfaces whose radii are rand r+hVUU!X'
gap distribution is calculated. respectivel y.
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1----1
1J1SL 1
- - Tool electrode I I
--0--- Workpiece ~------~ I
I
I
Power source of 1
higher voltage
---- "''0'''- . . __ Tool 90V I
I
--- _-- 170V - electrode
------._- ..... -
...
240V-=- I
I
I
I
Pulse generator
0.12 0.14 0.16 0.18 4
Fig.6 Discharge circuit used to increase
Gap width, mm
the gap width
Fig.5 Dependence of the volume of workpiece
and tool electrode removed per pulse Tool electrode surface
discharge on the gap width Ve=Sed e
Workpiece surface
width, a power supply of higher voltage, 170V or
240V, was connected in parallel with the pulse
generator, as shown in Fig. 6. Here, the FET for
switching the high voltage and the diodes are
necessary because, if the high voltage is
superimp.osed without them, the averaged gap
voltage mcreases and the servo mechanism feeds
the tool electrode so that the averaged gap voltage
decreases and equals the reference voltage of the
servo mechanism, which will keep the gap width
unchanged. Fig.7 Influence of curvature on the depth
. The circuit shown in Fig. 6 cannot give a gap of removal per pulse discharge
WIdth narrower than O.13rnrn without replacing the
power source of the pulse generator used in our reference planes, each of which is attached to an
research with one whose open voltage is lower electrode. The measurement is carried out after
than 90V. Therefore, in order to get a narrower the tool electrode is moved a known distance from
gap without replacing the power source, the the position which has been maintained against the
reference voltage of the servo mechanism was workpiece during the machining process.
decreased. However, this increased the discharge
frequency, which changed the gap temperature and 3.2.2 Influence of curvature
As shown in Fig. 7, Se is the area of the mesh
the debris p~i~le concentration. Then, the change
of gap condItions affects the thickness of the section at point P on the tool electrode. Suppose
carbon layer deposited on the tool electrode area Sw and point Q on the workpiece are facing
surface16) resulting in a change of the rate of tool Se and P, respectively, in the direction normal to
~lectrode wear13)-16). Therefore, the discharge the tool electrode surface, then the relationship
mterval was adjusted to be longer so that the same between Sw and Se is given by:
discharge frequency was obtained. = (1
:0 . obtain the data in Fig. 5, we used a
cylmdncal tool electrode whose cross section has
Sw + h/r;c)(1 + h/ry ) Se ' (3)
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Contour of
tool electrode
Discharge spot
Contour of
bubble electrode
Scattered debris particles Fig.9 Caculation of the contour of
bubble and relocation of debris
Fig.8 Distribution of newly produced particles
debris particles
3.3 Calculation of Debris Particles Concentration flow whose source is at the center of two parallel
3.3.1 Distribution of newly produced debris circular plates whose radius is 1£). Assuming that
particles the radius of the source is equal to the radius of
Yoshida and Kunieda 18) found that most of the the discharge crater a, the radial velocity v £) at
debris particles produced by a pulse discharge in r=a is given by:
the dielectric liquid are distributed on the periphery
of the bubble which is generated by the same
discharge. Hence, newly produced debris particles (4)
are distributed uniformly in all the directions to the
mesh sections on the periphery of the bubble as
shown in Fig. 8. The contour of the bubble can
be obtained by the method described in the next where Po is the pressure at the source. From the
paragraph. The number of debris particles newly equation of continuity, the expanded distance b £)
produced can be calculated by dividing the total can be roughly estimated by:
volume removed from both electrodes per pulse
discharge, which is the summation of Ve and Vw,
by the averaged volume of one debris particle
A " ~ Poh\ . (5)
6~
which can be measured using an optical
microscope. The debris particles which already Here we can determine the constant A from the
exist at the mesh section where the discharge next integral equation:
occurs are redistributed in the same way as the
newly produced debris particles are distributed.
Vo ="2hI be2 de, (6)
3.3.2 Contour of bubble
A bubble is formed according to the evaporating where Vo is the measured volume of the bubble
and cracking of the dielectric liquid. For generated per pulse discharge.
simplicity, it is assumed that the bubble expansion
is a steady incompressible flow between two 3.3.3 Relocation of debris particles
parallel plates which is generated by a source We assumed that the debris particles which
placed at the discharge spot, and that its density p already exist at the mesh sections, except at the
and viscosity f.1 are equal to those of the dielectric discharging mesh section, are also relocated due to
liquid. the expansion of the bubble. From the equation of
The expansion b B in the e -direction depends continuity for the dielectric liquid we can obtain
on the distance 1£) between the source and the the displacement 01 £) of the dielectric at point W
boundary of the working surface due to the viscous as shown in Fig. 9.
force of the dielectric liquid. Here, be can be
roughly estimated from the velocity of a radial
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- - experiment
.......... simulation
0.04
~ki:(21 x
B I'~
0 2l ' \~~~: j
-10 0 10
Fig.lO Distribution of depth of the layer Fig1!. Distribution of depth of the layer
removed on the tool electrode removed on the workpiece
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--experiment
Proc. of ISEM Xl, (1995), pp.315-324 .
..._,.- simulation A 4) T. Masuzawa, T. Sata, N. Kinoshita: The Role
o.
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..c::~
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-0 Breakdown of a Liquid Dielectric, J.
.~
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0.
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-10 0 10 7) B. M. Schumacher: About the Role of Debris
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Improved Jet Flushing for EDM, Annals of
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5. CONCLUSIONS Understanding Discharge Location Movements
During EDM, Proc. ISEM 10, (1992), pp.144-
We simulated the machining accuracy of die- 149.
sinking EDM using the newly developed simulation 11) M. Kunieda, M. Mori: Relation between
algorithm which describes the procedure of Debris Concentration and Discharge Gap
searching for the next discharge location based on Length in EDM Process, Proc. of Asian
an index which correlates with the gap width and Electrical-Machining Symposium '95, pp. 1-6.
the debris particle concentration. Although the 12) K. K. B. Hon, S. C. Li: An Experimental
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into account many factors, such as tool electrode EDM, ISEM 9, (1989), pp.321-324.
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inclination of the tool electrode, and debris particle Electrode Erosion Caused by Transient Arc
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and Cathode in EDM Process, IJEM, 1,
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