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Modeling of Melt-Pool Formation and Material Removal in Micro Electro-Discharge Machining

[+] Author Affiliations
Soham S. Mujumdar, Davide Curreli, Shiv G. Kapoor, David Ruzic

University of Illinois at Urbana-Champaign, Champaign, IL

Paper No. MSEC2014-4108, pp. V001T03A014; 14 pages
  • ASME 2014 International Manufacturing Science and Engineering Conference collocated with the JSME 2014 International Conference on Materials and Processing and the 42nd North American Manufacturing Research Conference
  • Volume 1: Materials; Micro and Nano Technologies; Properties, Applications and Systems; Sustainable Manufacturing
  • Detroit, Michigan, USA, June 9–13, 2014
  • Conference Sponsors: Manufacturing Engineering Division
  • ISBN: 978-0-7918-4580-6
  • Copyright © 2014 by ASME


This paper presents a μ – EDM melt-pool model to predict workpiece (anode) material removal from a single discharge μ – EDM process. To model the melt-pool heat transfer and fluid flow equations are solved in the domain containing dielectric and workpiece material. A level set method is used to identify solid and liquid fractions of the workpiece material when the material is molten by μ – EDM plasma heat flux. The plasma heat flux, plasma pressure and the radius of the plasma bubble have been estimated by a μ – EDM plasma model and serve as inputs to the melt-pool model to predict the volume of material removed from the surface of the workpiece. Experiments are carried out to study the effect of inter-electrode voltage and gap distance on the crater size. For inter-electrode voltage in the range of 100–150 V and gap distance of 0.5–2 μm, the model predicts crater diameter in the range of 150–165 μm and maximum crater depth of 25–35 μm for discharge duration of 5 μs. The crater sizes for most of experimental craters at higher gap distances show good agreement with the simulated crater shapes. However, at lower gaps, the model over-predicts the crater size.

Copyright © 2014 by ASME



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