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TECHNICAL PAPERS

Modeling of a Single Resistance Capacitance Pulse Discharge in Micro-Electro Discharge Machining

[+] Author and Article Information
Sandeep Dhanik

Department of Mechanical Engineering,  Indian Institute of Technology, Bombay, Powai, Mumbai 400 076, India

Suhas S. Joshi1

Department of Mechanical Engineering,  Indian Institute of Technology, Bombay, Powai, Mumbai 400 076, Indiassjoshi@me.iitb.ac.in

1

To whom correspondence should be addressed.

J. Manuf. Sci. Eng. 127(4), 759-767 (Feb 08, 2005) (9 pages) doi:10.1115/1.2034512 History: Received August 02, 2004; Revised February 08, 2005

Micro-EDM (electro discharge machining) is a derived form of EDM process especially evolved for micro-machining. The use of resistance capacitance pulse generator, an advanced controller for machining in smaller interelectrode gaps and with lower discharge energies than in EDM, makes the material removal characteristics of a single discharge in micro-EDM different from that of the EDM. A comprehensive model predicting the material removal in a single discharge in micro-EDM is conceptualized. The model incorporates various phenomena in the prebreakdown period. It considers plasma as a time-variable source of energy to the cathode and anode to evaluate material removal at the electrodes. The plasma temperature and radius of the crater at the cathode (workpiece) predicted using the model were found to agree well with the experimental data in the literature.

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Copyright © 2005 by American Society of Mechanical Engineers
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Figures

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Figure 1

The discharge characteristic of RC pulse and RC relaxation circuits

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Figure 2

Proposed model of breakdown phase. (a) Emission of prebreakdown current and heating at micro peaks. (b) Bubble nucleation at micro-peak. (c) Reaching electron impact criteria at bubble interface. (d) Bubble elongation towards anode. (e) Bubble abridged the interelectrode gap and fully developed plasma channel at the end of the breakdown phase.

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Figure 3

(a) Plasma channel with cylindrical axis representation. (b) Cross sectional view of cylindrical plasma.

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Figure 4

Model of plasma heat transfer mechanisms and current contributing factors

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Figure 5

(a) Typical electric potential distribution in the interelectrode gap. (b) Potential profile in the sheath region.

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Figure 6

Nonuniform discharge, heating of cathode and anode

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Figure 7

Nonuniform heat input to cathode with time

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Figure 8

Plasma temperature vs. time for various interelectrode gaps

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Figure 9

Theoretical vs. experimental values of crater radius at the cathode for various levels of discharge energies

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