Simulation Analysis Of Deteriorated Layer And Residual Stresses On Surface Of Edm Workpiece

One of the most important properties of the surface cut by electrical discharge machining(EDM)is deteriorated layer and residual stress.To be able to study the deteriorated layer and residual stress of SiC ceramics in EDM,the numerical analysis of single and multiple pulse analysis is done in electrical discharge machining under the proper boundary conditions,the Gaussian distribution of heat flux with constant temperature material properties of SiC is considered for analysis with constant pulse on time and variable plasma radius.The discharge process of SiC in EDM is analyzed by simulation.During discharge,a higher-pressure gradient was recorded in the melting area.It was also discovered that the melting zone and the solid region in contact with the melting region had a higher stress gradient.The pressure gradient and shear stress field are the primary causes of the discharge crater bulge.With regard to machining settings,the residual stress pattern is determined to remain constant.As a result,a unit amplitude shape function is suggested to describe change in curvature with respect to removal depth.The proposed form is a special case of the Gauss Distribution;it is the sum of two Gaussian peaks with identical amplitude and pulse width but opposite centre positions,represented by three constant coefficients.Using ANSYS software,a two-dimensional axi-symmetric model is designed to anticipate changes in temperature and residual stresses over time in SiC workpiece.When a spark occurs,the model recognizes distinct zones on the workpiece,such as melting zones,heat impact zones,boiling zones,and so on.During the EDM procedure,residual stresses build up in all directions around the crater border,according to the FEM research.These residual stresses are tensile as well as compressive,and they stay in tiny quantities in the workpiece after a single spark,but they can accumulate over time,causing surface damage in the form of micro-cracks.The development of residual stresses shows the site of failure in the workpiece,according to the FEM analysis.In each instance,experimental findings are used to demonstrate agreement with the suggested form.ANSYS software is used to build the model which solves the underlying governing equations and the boundary conditions unique to the problem using finite-element technique.