Annales De Chimie-science Des Materiaux | 2019
Electro Thermal Modelling of Electrical Discharge Machining of Be-Cu Alloy by Varying Fraction of Energy
Abstract
Received: 12 February 2019 Accepted: 20 May 2019 Beryllium Copper (Be-Cu) alloy are advanced engineering alloy bearing high strength, high wear resistance, Corrosion resistance and nonmagnetic nature. These properties of Beryllium copper make it impossible to machining through Conventional machining process. Electrical Discharge machining (EDM) is a revolution to machine any type of harder material (Electrically conductive) without any physical pressure. EDM is best suitable to machine BeCu alloy for small holes and intricate shape used in heat exchanger. To know the best suitable input parameters for improving the machining efficiency of EDM numerical analysis is always required. In this study a mathematical modeling of Be-Cu alloy machined by EDM has been performed by finite element modeling (FEM) method. A 3D axi-symmetric computational domain has been considered for the analyses confined by proper boundary condition. The numerical simulation has been performed for single discharge machining. The model has been validated with the experimental results. Simultaneously the Material Removal Rate (MRR) has been calculated with varying Discharge Current (I) (8, 10, 12 A), Fractions of heat (Fc) (18 %, 20 %, 22 %) and Pulse On time (Ton) (100,150, 200 μS). The lowest error of 4.55 % (in MRR) between numerical model and experimental results has been determined at 10A current.