Investigating the effect of tool material on performance parameters in electric discharge machining through FEM

The study aims to fill the gap in the existing literature by investigating the effects of various tool materials, including copper, tungsten carbide, and brass, on performance parameters in electric discharge machining (EDM) simulations. The authors developed a modified gaussian heat flux equation that incorporates the electrical resistivity of both the tool and workpiece, based on prior experimental investigations. The authors further developed a finite element model that incorporates the modified Gaussian heat flux equation, spark radius, and fraction of heat transferred to workpiece as a function of pulse on time and pulse current, latent heat, specific heat values, and thermal conductivity properties. The outcomes of the simulation indicated that the Cu tool exhibited the minimum MRR and SR values when subjected to a current of 9 amps and a duty cycle of 0.4, as well as a current of 12 amps and a duty cycle of 0.6. The results also indicate that the brass tool displayed marginally elevated MRR and SR, whereas the Tungsten carbide tool exhibited the highest MRR and SR. The simulation results for all three tool materials showed similar trends, consistent with prior research. Also, an increase in gap voltage, pulse current and duty cycle was observed to correspond with increased MRR and SR. Authors also observed that as electrode material electrical conductivity increased, so did workpiece material residual stresses. These results assist with the choice of tool materials for EDM processes, allowing for finer control over performance parameters and greater machining efficiency.