Research Papers

Analytical Simulation of Random Textures Generated in Electrical Discharge Texturing

[+] Author and Article Information
S. Jithin, Upendra V. Bhandarkar

Department of Mechanical Engineering,
Indian Institute of Technology Bombay,
Mumbai 400076, India

Suhas S. Joshi

Department of Mechanical Engineering,
Indian Institute of Technology Bombay,
Mumbai 400076, India
e-mail: ssjoshi@iitb.ac.in

1Corresponding author.

Manuscript received March 1, 2017; final manuscript received July 11, 2017; published online September 13, 2017. Assoc. Editor: Y. B. Guo.

J. Manuf. Sci. Eng 139(11), 111002 (Sep 13, 2017) (14 pages) Paper No: MANU-17-1122; doi: 10.1115/1.4037322 History: Received March 01, 2017; Revised July 11, 2017

Textured functional surfaces are finding applications in the fields of bioengineering, surface energy, hydrodynamics, lubrication, and optics. Electrical discharge machining (EDM), which is normally used to generate smoother surface finish on various automotive components and toolings, can also generate surfaces of rough finish, a desirable characteristic for texturing purposes. There is a lack of modeling efforts to predict the surface textures obtained under various EDM operating conditions. The aim of the current work is to capture the physics of the electrical discharge texturing (EDT) on a surface assuming random generation of multiple sparks with respect to (i) space, (ii) time, and (iii) energy. A uniform heat disk assumption is taken for each individual spark. The three-dimensional (3D) texture generated is utilized to evaluate a 3D roughness parameter namely arithmetic mean height, Sa. Surface textures obtained from the model are validated against experimentally obtained ones by comparison of distribution of Ra values taken along parallel sections along the surface. It was found that the distribution of simulated Ra values agrees with that of experimental Ra values.

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Fig. 1

Fc versus spark energy based on the results in Ref. [18]

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Fig. 2

Plots for %PFE : (a) 3D Scatterplot of %PFE versus I versus ton and (b) best fit model Poly12

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Fig. 3

Planar area with 1001 × 1001 points (a) input heat flux circle C1 and (b) top view of crater (circle C2) and half heat flux region (C3  −  C2)

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Fig. 4

Occurrence of simultaneous craters: (a) initial crater, (b) craters without overlap, (c) craters with touching boundaries, and (d) craters with overlap

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Fig. 5

Possible overlap of craters

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Fig. 6

Normal distribution for spark energies

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Fig. 8

A sample melt region: (a) 2D axisymmetric melt profile and (b) 3D crater shape obtained by rotating the 2D axisymmetric melt profile

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Fig. 9

Variation in crater geometry with change in spark energy

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Fig. 10

Comparison of crater radius from model with experimental data

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Fig. 11

Surface texture obtained at different parameter settings: (a) 20 A, 200 μs, 50 V, (b) 40 A, 200 μs, 50 V, (c) 20 A, 400 μs, 50 V, and (d) 20 A, 200 μs, 80 V

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Fig. 12

Variation of Sa with (a) current, (b) pulse on-time, and (c) voltage

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Fig. 13

Variation of Sa(μm) with (a) current (I) and (b) pulse on-time (ton)

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Fig. 14

Sections along (a) experimental and (b) simulated surfaces

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Fig. 15

Distribution of Ra values under different parameter settings: (a) 30 A, 100 μs and 65 V and (b) 10 A, 300 μs and 65 V




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