A novel thermo-hydraulic coupling model to investigate the crater formation in electrical discharge machining

摘要

A novel thermo-hydraulic coupling model was proposed in this study to investigate the crater formation in electrical discharge machining (EDM). The temperature distribution of workpiece materials was included, and the crater formation process was explained from the perspective of hydrodynamic characteristics of the molten region. To better track the morphology of the crater and the movement of debris, the level-set method was introduced in this study. Simulation results showed that the crater appears shortly after the ignition of the discharge, and the molten material is removed by vaporizing in the initial stage, then by splashing at the following time. The driving force for the detachment of debris in the splashing removal stage comes from the extremely large pressure difference in the upper part of the molten region, and the morphology of the crater is also influenced by the shearing flow of molten material. It was found that the removal ratio of molten material is only about 7.63% under the studied conditions, leaving most to form the re-solidification layer on the surface of the crater. The size of the crater reaches the maximum at the end of discharge duration then experiences a slight reduction because of the reflux of molten material after the discharge. The results of single pulse discharge experiments showed that the morphologies and sizes between the simulation crater and actual crater are good at agreement, verifying the feasibility of the proposed thermo-hydraulic coupling model in explaining the mechanisms of crater formation in EDM.