Experimental study of distribution of energy during EDM process for utilization in thermal models

Electrical discharge machining (EDM) has steadily gained importance over the years because of its ability to cut and shape a wide variety of materials and complicated shapes with high accuracy. The effectiveness of the EDM process is evaluated in terms of the material removal rate, relative wear ratio and the surface roughness of the work piece. The input discharge energy during this process is distributed to various components of the process, which further influences the material removal rate and other machining characteristics like surface roughness. Since during this process the electrical energy is converted into heat energy, hence the theoretical modeling of this process is based upon the heat transfer equations and in all existing thermal models the fraction of the energy transferred to the workpiece, is one of the important parameters. The accurate prediction of the fraction of energy effectively transferred to the workpiece will help to reduce the errors of the thermal models. In this study experiments have been performed to study the percentage fraction of energy transferred to the workpiece utilizing heat transfer equations, at different EDM parameters. This study also relates the optimum parameters with the optimum utilization of input discharge energy and hence will help to improve the technological performance of this process. (C) 2012 Elsevier Ltd. All rights reserved.