Numerical Modelling of Electro-Discharge Machining Process Using Moving Mesh Feature☆

Abstract This paper is concerned with numerical modelling of Electro Discharge Machining (EDM) process using moving mesh feature. Coefficient of erosion was defined and found to be constant using analytical equations. This was validated by conducting experiments on electro discharge machining. Then, the machining process was modelled in software using the coefficient of erosion. When the same conditions were applied in the real time machining, the results obtained were in good agreement with that of the software results. The application of software modelling was demonstrated to determine the process efficiency of drilling process. The process efficiency helps to find out if there is any scope for improvement in process and therefore enhanced productivity. Also, machining time which is one of the critical factors in micro-EDM process was predicted using software. This greatly saves time and resources and also, the difficulty in manufacture of micro sized electrodes for research is greatly reduced. A comparison study was performed with the use of conventional and concentric electrode for drilling concentric micro size holes. It was concluded that reduced machining time and perfect concentricity was observed when conventional electrodes were replaced by concentric electrodes. Yet another study was performed to justify the reduction in machining time due to usage of conductivity enhancement rings in the direction of passage of current to enhance current flow by avoiding air gap insulation. Thus, software modelling helps to perform research by predicting machining time without the need of real time experimentation.