Skip to main content
Disciplines
Automotive Business IT + Informatics Construction + Real Estate Electrical Engineering + Electronics Energy + Sustainability Insurance + Risk Finance + Banking Management + Leadership Marketing + Sales Mechanical Engineering + Materials
Events
DE
EN
Books
Journals
Topic Page
Marketing
Start single access now
Access for companies
EXTENDED SEARCH
Log in
Top
Published in:
Study on the Delamination of GFRP Composites in Drilling: A Finite Element Model Read chapter Read first chapter

2018 | OriginalPaper | Chapter

FEM Analysis of Different Materials Based on Explicit Dynamics ANSYS in Electrochemical Discharge Machine

Authors : Pravin Pawar, Raj Ballav, Amaresh Kumar

Published in: Simulations for Design and Manufacturing

Publisher: Springer Singapore

Log in

Activate our intelligent search to find suitable subject content or patents.

search-config
loading …

Abstract

The electrochemical discharge machining is a hybrid machining process. This process includes the electrochemical and electro-discharge machining which is employed to machining of conducting as well as nonconducting materials. In this chapter, the explicit dynamics ANSYS was used for the analysis of strain, stress, and deformation of different materials in electrochemical discharge machine model. The solid model of the electrochemical discharge machine is developed in ANSYS Workbench. By using ANSYS, the force and displacement were applied to the cathode tool on the different workpiece materials, and the equivalent elastic strain, equivalent (von Mises) stress, and total deformation were evaluated under certain conditions. The obtained results were compared with one another to understand the characteristics of different materials.

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

  • über 102.000 Bücher
  • über 537 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Finance + Banking
  • Management + Führung
  • Marketing + Vertrieb
  • Maschinenbau + Werkstoffe
  • Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

inform now

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

  • über 67.000 Bücher
  • über 390 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Maschinenbau + Werkstoffe




 

Jetzt Wissensvorsprung sichern!

inform now

Springer Professional "Wirtschaft"

Online-Abonnement

Mit Springer Professional "Wirtschaft" erhalten Sie Zugriff auf:

  • über 67.000 Bücher
  • über 340 Zeitschriften

aus folgenden Fachgebieten:

  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Finance + Banking
  • Management + Führung
  • Marketing + Vertrieb
  • Versicherung + Risiko




Jetzt Wissensvorsprung sichern!

inform now
previous chapter Dynamic Analysis of Robotic Manipulator for Incremental Sheet Metal Forming
next chapter Molecular Dynamics Simulation Study of Neck Growth in Micro-selective Laser Sintering of Copper Nanoparticles
Literature
1.
Dixit, P. M., & Dixit, U. S. (2008). Modeling of metal forming and machining processes: by finite element and soft computing methods. Springer Science & Business Media.
2.
Jain, V. K. (2008). Advanced (non-traditional) machining processes. Machining: Fundamentals and recent advances (pp. 299–327). London: Springer.CrossRef
3.
Singh, T., & Dvivedi, A. (2016). Developments in electrochemical discharge machining: A review on electrochemical discharge machining, process variants and their hybrid methods. International Journal of Machine Tools and Manufacture, 105, 1–13.CrossRef
4.
Wuthrich, R. (2009). Machining with electrochemical discharges—An overview. Micro and nano technologies, micromachining using electrochemical discharge phenomenon (pp. 1–9). Boston: William Andrew Publishing.
5.
Kurafuji, H., & Suda, K. (1968). Electrical discharge drilling of glass. Annals CIRP, 16, 415–419.
6.
Crichton, I. M., & McGeough, J. A. (1985). Studies of the discharge mechanisms in electrochemical arc machining. Journal of Applied Electrochemistry, 15(1), 113–119.CrossRef
7.
Gupta, K., Perveen, A., & Molardi, C. (2017). Machining of glass materials: An overview. In Advanced manufacturing technologies: Modern machining, advanced joining, sustainable manufacturing (pp. 23–47). Springer International Publishing.
8.
Wuthrich, R., & Fascio, V. (2005). Machining of non-conducting materials using electrochemical discharge phenomenon—An overview. International Journal of Machine Tools and Manufacture, 45(9), 1095–1108.CrossRef
9.
Paul, L., & Hiremath, S. S. (2016). Experimental and theoretical investigations in ECDM process—An overview. Procedia Technology, 25, 1242–1249.CrossRef
10.
Goud, M., Sharma, A. K., & Jawalkar, C. (2016). A review on material removal mechanism in electrochemical discharge machining (ECDM) and possibilities to enhance the material removal rate. Precision Engineering, 45, 1–17.CrossRef
11.
Pawar, P., Ballav, R., & Kumar, A. (2015). Revolutionary developments in ECDM process: An overview. Materials Today: Proceedings, 2(4–5), 3188–3195.CrossRef
12.
Celik, H. K. (2017). Determination of bruise susceptibility of pears (Ankara variety) to impact load by means of FEM-based explicit dynamics simulation. Postharvest Biology and Technology, 128, 83–97.CrossRef
13.
Callister, W. D., & Rethwisch, D. G. (2014). Materials science and engineering: An introduction (9th ed.). New York: Wiley.
14.
Kulkarni, A., Sharan, R., & Lal, G. K. (2002). An experimental study of discharge mechanism in electrochemical discharge machining. International Journal of Machine Tools and Manufacture, 42(10), 1121–1127.CrossRef
15.
Singh, Y. P., Jain, V. K., Kumar, P., & Agrawal, D. C. (1996). Machining piezoelectric (PZT) ceramics using an electrochemical spark machining (ECSM) process. Journal of Materials Processing Technology, 58(1), 24–31.CrossRef
16.
Lim, H. J., Lim, Y. M., Kim, S. H., & Kwak, Y. K. (2001). Self-aligned micro tool and electrochemical discharge machining (ECDM) for ceramic materials. Proceedings of SPIE, 4416, 348–353.CrossRef
17.
Zheng, Z. P., Cheng, W. H., Huang, F. Y., & Yan, B. H. (2007). 3D microstructuring of Pyrex glass using the electrochemical discharge machining process. Journal of Micromechanics and Microengineering, 17(5), 960–966.CrossRef
18.
Wuthrich, R., Spaelter, U., & Bleuler, H. (2006). The current signal in spark-assisted chemical engraving (SACE): What does it tell us? Journal of Micromechanics and Microengineering, 16(4), 779–785.CrossRef
19.
Ziki, J. D. A., & Wuthrich, R. (2015). Nature of drilling forces during spark assisted chemical engraving. Manufacturing Letters, 4, 10–13.CrossRef
20.
Allagui, A., & Wuthrich, R. (2009). Gas film formation time and gas film life time during electrochemical discharge phenomenon. Electrochimica Acta, 54(23), 5336–5343.CrossRef
21.
Cheng, C. P., Wu, K. L., Mai, C. C., Yang, C. K., Hsu, Y. S., & Yan, B. H. (2010). Study of gas film quality in electrochemical discharge machining. International Journal of Machine Tools and Manufacture, 50(8), 689–697.CrossRef
22.
Wuthrich, R., & Hof, L. A. (2006). The gas film in spark assisted chemical engraving (SACE)—A key element or micro-machining applications. International Journal of Machine Tools and Manufacture, 46(7), 828–835.CrossRef
23.
Yang, C. K., Cheng, C. P., Mai, C. C., Wang, A. C., Hung, J. C., & Yan, B. H. (2010). Effect of surface roughness of tool electrode materials in ECDM performance. International Journal of Machine Tools and Manufacture, 50(12), 1088–1096.CrossRef
24.
Ziki, J. D. A., Hof, L. A., & Wuthrich, R. (2015). The machining temperature during spark assisted chemical engraving of glass. Manufacturing Letters, 3, 9–13.CrossRef
25.
Didar, T. F., Dolatabadi, A., & Wuthrich, R. (2009). Local hardness and density variation in glass substrates machined with spark assisted chemical engraving (SACE). Materials Letters, 63(1), 51–53.CrossRef
26.
Bhattacharyya, B., Doloi, B. N., & Sorkhel, S. K. (1999). Experimental investigations into electrochemical discharge machining (ECDM) of non-conductive ceramic materials. Journal of Materials Processing Technology, 95(1), 145–154.CrossRef
27.
Basak, I., & Ghosh, A. (1996). Mechanism of spark generation during electrochemical discharge machining: A theoretical model and experimental verification. Journal of Materials Processing Technology, 62(1–3), 46–53.CrossRef
28.
Liu, J. W., Yue, T. M., & Guo, Z. N. (2010). An analysis of the discharge mechanism in electrochemical discharge machining of particulate reinforced metal matrix composites. International Journal of Machine Tools and Manufacture, 50(1), 86–96.CrossRef
29.
Fascio, V., Wuthrich, R., & Bleuler, H. (2004). Spark assisted chemical engraving in the light of electrochemistry. Electrochimica Acta, 49(22), 3997–4003.CrossRef
30.
Kamaraj, A. B., Jui, S. K., Cai, Z., & Sundaram, M. M. (2015). A mathematical model to predict overcut during electrochemical discharge machining. The International Journal of Advanced Manufacturing Technology, 81(1–4), 685–691.CrossRef
31.
Bhondwe, K. L., Yadava, V., & Kathiresan, G. (2006). Finite element prediction of material removal rate due to electro-chemical spark machining. International Journal of Machine Tools and Manufacture, 46(14), 1699–1706.CrossRef
32.
Wei, C., Xu, K., Ni, J., Brzezinski, A. J., & Hu, D. (2011). A finite element based model for electrochemical discharge machining in discharge regime. The International Journal of Advanced Manufacturing Technology, 54(9), 987–995.CrossRef
33.
Skrabalak, G., Zybura-Skrabalak, M., & Ruszaj, A. (2004). Building of rules base for fuzzy-logic control of the ECDM process. Journal of Materials Processing Technology, 149(1), 530–535.CrossRef
34.
Coteata, M., Pop, N., Schulze, H. P., Slatineanu, L., & Dodun, O. (2016). Investigation on hybrid electrochemical discharge drilling process using passivating electrolyte. Procedia CIRP, 42, 778–782.CrossRef
35.
Gautam, N., & Jain, V. K. (1998). Experimental investigations into ECSD process using various tool kinematics. International Journal of Machine Tools and Manufacture, 38(1–2), 15–27.CrossRef
36.
Jui, S. K., Kamaraj, A. B., & Sundaram, M. M. (2013). High aspect ratio micromachining of glass by electrochemical discharge machining (ECDM). Journal of Manufacturing Processes, 15(4), 460–466.CrossRef
37.
Huang, S. F., Liu, Y., Li, J., Hu, H. X., & Sun, L. Y. (2014). Electrochemical discharge machining micro-hole in stainless steel with tool electrode high-speed rotating. Materials and Manufacturing Processes, 29(5), 634–637.CrossRef
38.
Dhanvijay, M. R., & Ahuja, B. B. (2014). Micromachining of ceramics by electrochemical discharge process considering stagnant and electrolyte flow method. Procedia Technology, 14, 165–172.CrossRef
39.
Zhang, Y., Xu, Z., Xing, J., & Zhu, D. (2015). Enhanced machining performance of micro holes using electrochemical discharge machining with super-high-pressure interior flushing. International Journal of Electrochemical Science, 10, 8465–8483.
40.
Han, M. S., Min, B. K., & Lee, S. J. (2007). Improvement of surface integrity of electro-chemical discharge machining process using powder-mixed electrolyte. Journal of Materials Processing Technology, 191(1), 224–227.CrossRef
41.
Pawar, P., Sinha, S., Kumar, A., & Ballav, R. (2014). Review on research trends in electrochemical discharge machining. In 4th National Conference on Recent in Advances in Manufacturing (RAM-2014) (pp. 132–137).
42.
Jain, V. K., Choudhury, S. K., & Ramesh, K. M. (2002). On the machining of alumina and glass. International Journal of Machine Tools and Manufacture, 42(11), 1269–1276.CrossRef
43.
Coteata, M., Ciofu, C., Slatineanu, L., Munteanu, A., & Dodun, O. (2009). Establishing the electrical discharges weight in electrochemical discharge drilling. International Journal of Material Forming, 2, 673–676.CrossRef
44.
Abou Ziki, J. D., & Wuthrich, R. (2012). Tool wear and tool thermal expansion during micro-machining by spark assisted chemical engraving. The International Journal of Advanced Manufacturing Technology, 61(5), 481–486.CrossRef
45.
Han, M. S., Min, B. K., & Lee, S. J. (2008). Modeling gas film formation in electrochemical discharge machining processes using a side-insulated electrode. Journal of Micromechanics and Microengineering, 18(4), 045019.CrossRef
46.
Jiang, B., Lan, S., Ni, J., & Zhang, Z. (2014). Experimental investigation of spark generation in electrochemical discharge machining of non-conducting materials. Journal of Materials Processing Technology, 214(4), 892–898.CrossRef
47.
Yang, C. K., Wu, K. L., Hung, J. C., Lee, S. M., Lin, J. C., & Yan, B. H. (2011). Enhancement of ECDM efficiency and accuracy by spherical tool electrode. International Journal of Machine Tools and Manufacture, 51(6), 528–535.CrossRef
48.
Jain, V. K., & Adhikary, S. (2008). On the mechanism of material removal in electrochemical spark machining of quartz under different polarity conditions. Journal of Materials Processing Technology, 200(1), 460–470.CrossRef
49.
Mediliyegedara, T. K. K. R., De Silva, A. K. M., Harrison, D. K., & McGeough, J. A. (2005). New developments in the process control of the hybrid electro chemical discharge machining (ECDM) process. Journal of Materials Processing Technology, 167(2), 338–343.CrossRef
50.
Gao, C., Liu, Z., & Li, A. (2014). Study of micro drilling on Pyrex glass using spark assisted chemical engraving. Micro and Nanosystems, 6(1), 26–33.CrossRef
51.
Tandon, S., Jain, V. K., Kumar, P., & Rajurkar, K. P. (1990). Investigations into machining of composites. Precision Engineering, 12(4), 227–238.CrossRef
52.
Manna, A., & Narang, V. (2012). A study on micro machining of e-glass–fibre–epoxy composite by ECSM process. International Journal of Advanced Manufacturing Technology, 61, 1191–1197.CrossRef
53.
Madhavi, B. J., & Hiremath, S. S. (2016). Investigation on machining of holes and channels on borosilicate and sodalime glass using µ-ECDM setup. Procedia Technology, 25, 1257–1264.CrossRef
54.
Sahasrabudhe, A. H., & Ahuja, B. B. (2014). Experimental investigations for Al2O3 ceramic micro machining using ECDM process. In 5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014), December 12–14, 2014 (pp. 182-1–182-5), IIT Guwahati, Assam, India.
55.
Sarkar, B. R., Doloi, B., & Bhattacharyya, B. (2006). Parametric analysis on electrochemical discharge machining of silicon nitride ceramics. International Journal of Advanced Manufacturing Technology, 28(9), 873–881.CrossRef
56.
Doloi, B., Bhattacharyya, B., & Sorkhel, S. K. (1999). Electrochemical discharge machining of non-conducting ceramics. Defence Science Journal, 49(4), 331–338.CrossRef
57.
Didar, T. F., Dolatabadi, A., & Wuthrich, R. (2008). Characterization and modeling of 2D-glass micro-machining by spark-assisted chemical engraving (SACE) with constant velocity. Journal of Micromechanics and Microengineering, 18(6), 065016.CrossRef
58.
Fascio, V., Wuthrich, R., Viquerat, D., & Langen, H. (1999). 3D microstructuring of glass using electrochemical discharge machining (ECDM). In International Symposium on Micromechatronics and Human Science, IEEE (pp. 179–183).
59.
Cao, X. D., Kim, B. H., & Chu, C. N. (2009). Micro-structuring of glass with features less than 100 µm by electrochemical discharge machining. Precision Engineering, 33(4), 459–465.CrossRef
60.
Lee, E. S., Howard, D., Liang, E., Collins, S. D., & Smith, R. L. (2004). Removable tubing interconnects for glass-based micro-fluidic systems made using ECDM. Journal of Micromechanics and Microengineering, 14(4), 535–541.CrossRef
61.
Khairy, A. B. E., & McGeough, J. A. (1990). Die-sinking by electroerosion-dissolution machining. CIRP Annals-Manufacturing Technology, 39(1), 191–195.CrossRef
62.
Pawar, P., Ballav, R., & Kumar, A. (2015). Measurement analysis in electrochemical discharge machining (ECDM) process: A literature review. Journal of Chemistry and Chemical Engineering, 9, 140–144.
63.
Wuthrich, R., Spaelter, U., Wu, Y., & Bleuler, H. (2006). A systematic characterization method for gravity-feed micro-hole drilling in glass with spark assisted chemical engraving (SACE). Journal of Micromechanics and Microengineering, 16(9), 1891–1896.CrossRef
64.
Maillard, P., Despont, B., Bleuler, H., & Wuthrich, R. (2007). Geometrical characterization of micro-holes drilled in glass by gravity-feed with spark assisted chemical engraving (SACE). Journal of Micromechanics and Microengineering, 17(7), 1343–1349.CrossRef
65.
Mousa, M., Allagui, A., Ng, H. D., & Wuthrich, R. (2008). The effect of thermal conductivity of the tool electrode in spark-assisted chemical engraving gravity-feed micro-drilling. Journal of Micromechanics and Microengineering, 19(1), 015010.CrossRef
66.
Mallick, B., Ali, M.N., Sarkar, B.R., Doloi, B., & Bhattacharyya, B. (2014). Parametric analysis of electrochemical discharge micro-machining process during profile generation on glass. In 5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014), December 12–14 (pp. 540-1–540-6), IIT Guwahati, Assam, India.
67.
Paul, L., & Hiremath, S. S. (2013). Response surface modelling of micro holes in electrochemical discharge machining process. Procedia Engineering, 64, 1395–1404.CrossRef
68.
Coteata, M., Slatineanu, L., Dodun, O., & Ciofu, C. (2008). Electrochemical discharge machining of small diameter holes. International Journal of Material Forming, 1, 1327–1330.CrossRef
69.
Abou Ziki, J. D., & Wuthrich, R. (2013). Forces exerted on the tool-electrode during constant-feed glass micro-drilling by spark assisted chemical engraving. International Journal of Machine Tools and Manufacture, 73, 47–54.CrossRef
70.
Han, M. S., Min, B. K., & Lee, S. J. (2009). Geometric improvement of electrochemical discharge micro-drilling using an ultrasonic-vibrated electrolyte. Journal of Micromechanics and Microengineering, 19(6), 065004.CrossRef
71.
Rusli, M., & Furutani, K. (2012). Performance of micro-hole drilling by ultrasonic-assisted electro-chemical discharge machining. Advanced Materials Research, 445, 865–870.
72.
Wuthrich, R., Despont, B., Maillard, P., & Bleuler, H. (2006). Improving the material removal rate in spark-assisted chemical engraving (SACE) gravity-feed micro-hole drilling by tool vibration. Journal of Micromechanics and Microengineering, 16(11), N28–N31.CrossRef
73.
Elhami, S., & Razfar, M. R. (2017). Study of the current signal and material removal during ultrasonic-assisted electrochemical discharge machining. The International Journal of Advanced Manufacturing Technology, 1–9.
74.
Razfar, M. R., Behroozfar, A., & Ni, J. (2014). Study of the effects of tool longitudinal oscillation on the machining speed of electrochemical discharge drilling of glass. Precision Engineering, 38(4), 885–892.CrossRef
75.
Cheng, C. P., Wu, K. L., Mai, C. C., Hsu, Y. S., & Yan, B. H. (2010). Magnetic field-assisted electrochemical discharge machining. Journal of Micromechanics and Microengineering, 20(7), 075019.CrossRef
76.
Hajian, M., Razfar, M. R., & Movahed, S. (2016). An experimental study on the effect of magnetic field orientations and electrolyte concentrations on ECDM milling performance of glass. Precision Engineering, 45, 322–331.CrossRef
77.
Chak, S. K., & Rao, P. V. (2007). Trepanning of Al2O3 by electro-chemical discharge machining (ECDM) process using abrasive electrode with pulsed DC supply. International Journal of Machine Tools and Manufacture, 47(14), 2061–2070.CrossRef
78.
Schopf, M., Beltrami, I., Boccadoro, M., Kramer, D., & Schumacher, B. (2001). ECDM (electro chemical discharge machining), a new method for trueing and dressing of metal bonded diamond grinding tools. CIRP Annals-Manufacturing Technology, 50(1), 125–128.CrossRef
79.
Kulkarni, A. V., Jain, V. K., & Misra, K. A. (2011). Electrochemical spark micromachining: Present scenario. International Journal of Automation Technology, 5(1), 52–59.CrossRef
80.
Wuthrich, R., Fujisaki, K., Couthy, P., Hof, L. A., & Bleuler, H. (2005). Spark assisted chemical engraving (SACE) in microfactory. Journal of Micromechanics and Microengineering, 15(10), S276–S280.CrossRef
81.
Abou Ziki, J. D., Didar, T. F., & Wuthrich, R. (2012). Micro-texturing channel surfaces on glass with spark assisted chemical engraving. International Journal of Machine Tools and Manufacture, 57, 66–72.CrossRef
82.
Kulkarni, A. V. (2007). Electrochemical discharge machining process. Defence Science Journal, 57(5), 765–770.CrossRef
83.
Kabir, M. A., Lovell, M. R., & Higgs, C. F. (2008). Utilizing the explicit finite element method for studying granular flows. Tribology Letters, 29(2), 85–94.CrossRef
84.
Mitrovic, S. (2015). Three-dimensional nonlinear dynamic time history analysis of seismic site and structure response. Ph.D. Thesis, Faculty of Civil Engineering, University of Rijeka.
85.
Lee, K. M., & Liu, C. H. (2012). Explicit dynamic finite element analysis of an automated grasping process using highly damped compliant fingers. Computers & Mathematics with Applications, 64(5), 965–977.CrossRef
86.
Liu, Y. (2008). ANSYS and LS-DYNA used for structural analysis. International Journal of Computer Aided Engineering and Technology, 1(1), 31–44.CrossRef
87.
Jung, D. W. (1998). Study of dynamic explicit analysis in sheet metal forming processes using faster punch velocity and mass scaling scheme. Journal of Materials Engineering and Performance, 7(4), 479–490.MathSciNetCrossRef
88.
Hu, Y., Shao, Y., Chen, Z., & Zuo, M. J. (2011). Transient meshing performance of gears with different modification coefficients and helical angles using explicit dynamic FEA. Mechanical Systems and Signal Processing, 25(5), 1786–1802.CrossRef
Metadata
Title
FEM Analysis of Different Materials Based on Explicit Dynamics ANSYS in Electrochemical Discharge Machine
Authors
Pravin Pawar
Raj Ballav
Amaresh Kumar
Copyright Year
2018
Publisher
Springer Singapore
Book
Simulations for Design and Manufacturing

Print ISBN: 978-981-10-8517-8

Electronic ISBN: 978-981-10-8518-5

Copyright Year: 2018

DOI
https://doi.org/10.1007/978-981-10-8518-5_9

Premium Partners

    Image Credits