Numerical Simulation of Uneven Wear of Shaped Electrode in EDM

Tool wear has important effect on the accuracy of the machined surface in EDM and the cost of the manufacturing process. The prediction of tool wear, especially when a shaped electrode with complex profile is used, is always necessary. The study of shaped electrode wears showed that the curvature radius distribution of the electrode surface has a decisive impact on the electrode uneven wear. Based on this, an electrode uneven wear model that takes into account the electrode profile characteristics and the electrode feed path is proposed. The Numerical simulated tool wear of a shaped turbine blisk electrode is consistent with the experimental results.