Modeling and process simulation of vibration assisted workpiece in micro-EDM using FEM

Abstract

Purpose Micro-electro discharge machining (EDM) plays an important role in the fabrication of micro holes in an electrically conductive high-strength material. The flushing of debris poses a great challenge in the micro-EDM operation. The vibration of workpiece plays a significant role in the flushing of debris of the workpiece. Design/methodology/approach This study aims that the finite element analysis is performed using ANSYS software to find out the maximum displacement of the workpiece at a different location at different frequencies. For the convergence of this analysis, the natural frequency obtained from ANSYS is validated with some available literature. Findings The continuous up and down vibration of the workpiece results in the formation of vapor bubbles in a low-pressure region that contributes to material removal due to the fracture of bubbles. The vibration-assisted workpiece in the micro-EDM process causes the pressure variation of dielectric between the electrode and workpiece that enhances material removal rate because of cavitation. Originality/value In workpiece vibration-assisted micro-EDM, the selection of correct vibration frequency and displacement is of greater importance because improper frequency selection can cause bending of the wire electrode, affecting machining stability and short circuiting.