Experimental investigation and finite element simulation of AISI 304 during electro discharge machining

2018 ◽  
Vol 09 (04) ◽  
pp. 1850022 ◽  
Author(s):  
Munmun Bhaumik ◽  
Kalipada Maity
Keyword(s):  
Finite Element ◽  
Temperature Distribution ◽  
Thermal Model ◽  
304 Stainless Steel ◽  
Dielectric Fluid ◽  
Heat Distribution ◽  
Aisi 304 ◽  
Electro Discharge Machining ◽  
Temperature Isotherm ◽  
Pulse On Time

In this paper, a two-dimensional axisymmetric thermal model using finite element method (FEM) has been established for predicting the temperature distribution profile on the work piece during electro discharge machining (EDM) and obtained material removal rate (MRR) from the temperature isotherm. For prediction of MRR, the model utilizes some important features viz. size and shape of the heat source (Gaussian heat distribution), thermal properties of workpiece, amount of heat distribution among the dielectric fluid, workpiece and tool, material flushing efficiency and pulse off/on time, etc. ANSYS software was used for developing the thermal model for the single spark operation. For this investigation, AISI 304 stainless steel and tungsten carbide was used as workpiece and electrode material, respectively. A comparison study has been carried out for theoretical and experimental MRR for the effect of each process parameter viz. gap voltage, pulse on time and peak current. The temperature distribution along the radial and depth direction of the workpiece has been reported. The model was validated by comparing the theoretical MRR with the experimental MRR and found a good correlation between them.

Finite element modeling and analysis of powder mixed electric discharge machining process for temperature distribution and volume removal considering multiple craters

2014 ◽  
Vol 05 (03) ◽  
pp. 1450009 ◽  
Author(s):  
Hardeep Singh ◽  
Anirban Bhattacharya ◽  
Ajay Batish
Keyword(s):  
Finite Element ◽  
Temperature Distribution ◽  
Finite Element Modeling ◽  
Electric Discharge ◽  
Material Removal ◽  
Peak Temperature ◽  
Machining Process ◽  
Electric Discharge Machining ◽  
Element Modeling ◽  
Pulse On Time

Powder mixed electric discharge machining (PMEDM) is one of the modern developments in electric discharge machining (EDM) process. In the present work, finite element modeling has been carried out considering randomly oriented multiple sparks during PMEDM. Transient thermal analysis is done to obtain temperature distribution, volume removal, and proportion of volume removed by melting and evaporation at different current, pulse on time and fraction of heat that enters to work piece. Gradually growing spark behavior and Gaussian distribution of heat source is used to simulate multiple craters. Temperature distribution along radial direction shows peak temperature at center of spark and thereafter a gradual decrease with increase in radial distance. Along depth direction temperature sharply decreases that forms wider craters with shallow depth in PMEDM. Peak temperature and volume removal increases with current more rapidly. Volume removal by melting is much higher than evaporation at lower current settings and with higher current almost equal amount of material is removed by melting and evaporation thus reducing the re-solidification of melted material. Current plays a significant role behind the contribution of material removal by evaporation followed by fraction of heat. Increase in pulse on duration increases the total volume of material removal however does not significantly increase the proportion of volume removal by vaporization.

Influence of Laser Parameters on Residual Stress Field of AISI 304 Stainless Steel Induced by Laser Peening: A Finite Element Analysis

2006 ◽  
Author(s):  
Xiang Ling ◽  
Weiwei Peng
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Stainless Steel ◽  
Stress Field ◽  
Stress Corrosion ◽  
Compressive Stress ◽  
304 Stainless Steel ◽  
Laser Peening ◽  
Aisi 304 Stainless Steel ◽  
Aisi 304

The present paper established a non-linear elastic-plastic finite element method to predict the residual compressive stress distribution induced by Laser Peening (LP) in the AISI 304 stainless steel. The two dimensional FEA model considered the dynamic material properties at high strain rate (106/s) and the evaluation of loading conditions. Effects of laser power density, laser spot size, laser pulse duration, multiple LP processes and one/two-sided peening on the compressive stress field in the stainless steel were evaluated for the purpose of optimizing the process. Numerical results have a good agreement with the measurement values by X-ray diffraction method and also show that the magnitude of compressive stress induced by laser peening is greater than the tensile welding residual stress. So, laser peening is an effective method for protecting weldments against stress corrosion crack. The above results provide the basis for studying the mechanism on prevention of stress corrosion cracking in weld joint of type 304 stainless steel by laser peening.

Laser Transmission Welding of a Lap-Joint: Thermal Imaging Observations and three–dimensional Finite Element Modeling

2007 ◽  
Vol 129 (9) ◽  
pp. 1177-1186 ◽  
Author(s):  
L. S. Mayboudi ◽  
A. M. Birk ◽  
G. Zak ◽  
P. J. Bates
Keyword(s):  
Finite Element ◽  
Temperature Distribution ◽  
Laser Beam ◽  
Thermal Imaging ◽  
Thermal Model ◽  
Three Dimensional ◽  
Welding Process ◽  
Lap Joint ◽  
Laser Transmission Welding ◽  
Joint Geometry

Laser transmission welding (LTW) is a relatively new technology for joining plastic parts. This paper presents a three-dimensional (3D) transient thermal model of LTW solved with the finite element method. A lap-joint geometry was modeled for unreinforced polyamide (PA) 6 specimens. This thermal model addressed the heating and cooling stages in a laser welding process with a stationary laser beam. This paper compares the temperature distribution of a lap-joint geometry exposed to a stationary diode laser beam, obtained from 3D thermal modeling with thermal imaging observations. It is shown that the thermal model is capable of accurately predicting the temperature distribution when laser beam scattering during transmission through the polymer is included in the model. The weld dimensions obtained from the model have been compared with the experimental data and are in good agreement.

Derivation of Equations and the Heat Distribution Graphs in Vibration Assisted Machining and Comparison with the Conventional Machining

2012 ◽  
Vol 488-489 ◽  
pp. 1506-1510
Author(s):  
Reza Nosouhi ◽  
Hamid Montazerolghaem
Keyword(s):  
Finite Element ◽  
Temperature Distribution ◽  
Cutting Tool ◽  
Heat Distribution ◽  
Horizontal Vibration ◽  
Average Temperature ◽  
Cutting Zone ◽  
Wear Reduction ◽  
Conventional Machining ◽  
Good Agreement

The numerical analysis of the cutting zone average temperature and the temperature distribution of the chip and cutting tool are performed in this paper. To derivate the equations, the conditions of both conventional and horizontal vibration assisted machining are analyzed and the results are compared. The previous finite element results along with the experimental results show good agreement with the numerical results achieved from this research and explain the temperature reduction in the cutting zone. The results clearly show that horizontal vibration assisted machining excels the heat distribution in the tool and chip, which justifies the tool wear reduction in this process.

Thermal Imaging Studies and 3-D Thermal Finite Element Modeling of Laser Transmission Welding of a Lap-Joint

2006 ◽  
Author(s):  
L. S. Mayboudi ◽  
A. M. Birk ◽  
G. Zak ◽  
P. J. Bates
Keyword(s):  
Finite Element ◽  
Temperature Distribution ◽  
Laser Beam ◽  
Thermal Imaging ◽  
Thermal Model ◽  
Three Dimensional ◽  
Welding Process ◽  
Lap Joint ◽  
Laser Transmission Welding ◽  
Joint Geometry

Laser transmission welding (LTW) is a relatively new technology for joining plastic parts. This paper presents a three-dimensional (3-D) transient thermal model of LTW solved with the finite element method (FEM). A lap-joint geometry was modelled for unreinforced nylon 6 specimens. This thermal model addressed the heating and cooling stages in a laser welding process with a stationary laser beam. This paper compares the temperature distribution of a lap-joint geometry exposed to a stationary diode laser beam, obtained from 3-D thermal modelling with thermal imaging observations. It is shown that the thermal model is capable of accurately predicting the temperature distribution when laser beam scattering during transmission through the polymer is included in the model. The weld dimensions obtained from the model have been compared with the experimental data and are in good agreement.

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