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Modelling of ECM and EDM processes

(BQ) The modelling of ECM and EDM processes requires not one but several models to simulate the different phenomena that occur during machining. This paper reviews the models that have been developed to simulate each of these phenomena, e.g. potential models to calculate the current density distribution in ECM, thermal models for the plasma arc in EDM, moving boundary models to simulate the anodic dissolution in ECM and probabilistic models to determine the discharge location in EDM. In addition to discussing the relative merits of the techniques deployed in these models, the paper describes some salient applications and concludes with desirable future enhancements to these models. | CIRP Annals - Manufacturing Technology 62 (2013) 775–797 Contents lists available at SciVerse ScienceDirect CIRP Annals - Manufacturing Technology jou rnal homep age : ht t p: // ees .e lse vi er. com/ci rp/ def a ult . asp Modelling of ECM and EDM processes S. Hinduja (1)a,*, M. Kunieda (1)b a b School of Mechanical, Aerospace and Civil Engineering, The University of Manchester, UK Department of Precision Engineering, The University of Tokyo, Japan A R T I C L E I N F O A B S T R A C T Keywords: ECM EDM Modelling The modelling of ECM and EDM processes requires not one but several models to simulate the different phenomena that occur during machining. This paper reviews the models that have been developed to simulate each of these phenomena, e.g. potential models to calculate the current density distribution in ECM, thermal models for the plasma arc in EDM, moving boundary models to simulate the anodic dissolution in ECM and probabilistic models to determine the discharge location in EDM. In addition to discussing the relative merits of the techniques deployed in these models, the paper describes some salient applications and concludes with desirable future enhancements to these models. ß 2013 CIRP. 1. Introduction Because of their ability to machine tough, hard and heatresistant materials with complicated shapes, electro-chemical and electrical discharge machining (ECM and EDM) processes were first applied for the machining of aerospace alloys and die and mould making in the 1950s. Although both processes are categorized as electrical machining to differentiate them from conventional mechanical processes and both have similar machine tool structures and applications, their principle and machining characteristics are significantly different. The encouraging trend of ECM was not sustained for long because of inherent difficulties such as: (i) controlling/predicting the process due to electro-chemical, hydrodynamic and thermal factors; (ii) predicting the .