Electrical discharge machining modeling by coupling thermal analysis with deformed geometry feature

Electrical discharge machining (EDM) is a non-conventional machining process, widely used in the modern industry. The stochastic nature of the process and the complexity of the occurring phenomena are the major difficulties in modeling of EDM. The current study presents a novel approach on EDM modeling, by coupling a heat transfer thermal analysis with deformed geometry feature. The deformation rate was calculated proportional to the spark erosion, leading to more accurate and realistic results. To validate the simulations results, a series of experiments were carried out on AISI O1 work-steel, with changing machining parameters the pulse current and the pulse-on time. The model validation criteria were the geometry of the formed craters, the average white layer thickness, and the heat-affected zone thickness. The simulation results were in agreement with experimental ones, suggesting that deformed geometry feature is important and suitable in modeling of EDM.