Numerical analysis of the powder mixed electrical discharge machining (PMEDM) process for TZM-molybdenum superalloy using finite element method

Kapil Surani; Shailesh Patel; Mathan Kumar Mounagurusamy; Musaddak Maher Abdul Zahra; Hitesh Panchal; Md Irfanul Haque Siddiqui; Mohd Asif Shah; Natrayan L; Abhinav Kumar

doi:10.1063/5.0188809

AIP Advances (Feb 2024)

Numerical analysis of the powder mixed electrical discharge machining (PMEDM) process for TZM-molybdenum superalloy using finite element method

Kapil Surani,
Shailesh Patel,
Mathan Kumar Mounagurusamy,
Musaddak Maher Abdul Zahra,
Hitesh Panchal,
Md Irfanul Haque Siddiqui,
Mohd Asif Shah,
Natrayan L,
Abhinav Kumar

Affiliations

Kapil Surani: Department of Mechanical Engineering, Gujarat Power Engineering and Research Institute, Mehsana, Gujarat, India
Shailesh Patel: Department of Mechanical Engineering, Faculty of Engineering and Technology, Sankalchand Patel University, Visnagar, Gujarat, India
Mathan Kumar Mounagurusamy: Department of Computer Science and Engineering, Karpaga Vinayaga College of Engineering and Technology, Chennai, India
Musaddak Maher Abdul Zahra: Computer Techniques Engineering Department, College of Engineering and Technologies, Al-Mustaqbal University, Babil, Iraq
Hitesh Panchal: Department of Mechanical Engineering, Government Engineering College Patan, Patan, Gujarat, India
Md Irfanul Haque Siddiqui: Department of Mechanical Engineering, College of Engineering, King Saud University, Riyadh 11451, Saudi Arabia
Mohd Asif Shah: Department of Economics, Kebri Dehar University, Kebri Dehar, Ethiopia
Natrayan L: Department of Mechanical Engineering, Saveetha School of Engineering, SIMATS, Chennai, Tamil Nadu, India
Abhinav Kumar: Department of Nuclear and Renewable Energy, Ural Federal University Named After the First President of Russia, Boris Yeltsin, 19 Mira Street, 620002, Ekaterinburg, Russia

DOI: https://doi.org/10.1063/5.0188809
Journal volume & issue: Vol. 14, no. 2
pp. 025241 – 025241-14

Abstract

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The powder mixed electrical discharge machining (PMEDM) process was simulated via finite element analysis in the current study to assess heat behavior and material removal rate. The goal of this paper is to conduct a thorough experimental and thermal examination of electrical discharge machining (EDM) in order to forecast its cutting characteristics and subsequently optimize the output variables using a response surface methodology for simulations and choosing the most suitable set of process variables related to the PMEDM process. This study’s objective is to design a 2D axisymmetrical transient thermal model that might also describe the physics of material removal in a single spark PMEDM operation on a Titanium Zirconium Molybdenum (TZM) superalloy. ANSYS (version 9.1) software is used to perform transient heat transfer simulations to determine the temperature profile with the amount of material removal at different current, pulse on and off times, gap voltages, and fraction of heat that enters the specimen. The PMEDM process produced craters with a lower diameter and depth, which increased the material removal rate and enhanced the surfacing quality. Compared to the conventional EDM process, the inclusion of powder raised the heat flux given to the work material by 10%–12%. It has been determined that with the single spark modeling technique, the temperature significantly dropped in both the radial and depth directions. The computational results are compared with experimental observations for similar machining conditions, and both results agree satisfactorily.

Published in AIP Advances

ISSN: 2158-3226 (Online)
Publisher: AIP Publishing LLC
Country of publisher: United States
LCC subjects: Science: Physics
Website: http://aipadvances.aip.org/

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