Thermal Model for Single Discharge EDM Process Using COMSOL Multiphysics

K. Gajjar[1], U. Maradia[2], K. Wegener[2]
[1]Indian Institute of Technology Bombay, Mumbai, Maharshtra, India
[2]Institute for Process Tools and Manufacturing (IWF), Zurich, Switzerland

Electrical Discharge Machining (EDM) is a non-conventional process used for machining electrically conducting materials. In die sink-EDM, sparks are generated between tool and workpiece resulting in heating of both electrode surfaces and creating a melt pool of metal which leads to generation of new surfaces on cooling. Physical processes involved in electric discharge and material removal are not yet fully understood. So based on some simplifying assumptions an attempt has been made to study the temperature profiles and residual stresses prevailing in electrodes during single discharge EDM. Heat Conduction and Residual Thermal Stress modules of COMSOL have been used to develop this model for the process. And results obtained are further used to determine optimal operating conditions for the process.