11 research outputs found
Comparative experimental investigation and gap flow simulation in electrical discharge drilling using new electrode geometry
This study presents experimental and numerical investigation on the
effectiveness of electrode geometry on flushing and debris removal
in Electrical Discharge Drilling (EDD) process. A new electrode
geometry, namely side-cut electrode, was designed and manufactured
based on circular electrode geometry. Several drilling operations
were performed on stainless steel 304 using rotary tubular
electrodes with circular and side-cut geometries. Drilling
performance was characterized by Material Removal Rate (MRR),
Electrode Wear Rate (EWR), and Tool Wear Ratio (TWR). Dimensional
features and surface quality of drilled holes were evaluated based
on Overcut (OC), Hole Depth (HD), and Surface Roughness (SR).
Three-dimensional three-phase CFD models were built using
ANSYS FLUENT software to simulate the flow field at interelectrode
gap. Results revealed that the overall performance of side-cut
electrode was superior due to improved erosion rates and flushing
capabilities, resulting in production of deep holes with good
dimensional accuracy and surface quality
Influence of Press Ram Pulsation on Deep Drawability of Dual Phase Steel Sheet
A study of the influences of press ram pulsation on deep drawability of dual phase steel sheet is presented. General characteristics of deep drawing process, press ram pulsation technique and dual phase steels are briefly discussed. A finite element model is used to evaluate the influence of pulse motion profile of press ram on the thickness reduction of steel sheet and forming load. Commercial finite element software package DEFORM-3D is used for modelling and simulation of cylindrical cup drawing. The effects of superimposed low frequency vibrations of the press ram are investigated. Pulsation amplitudes of 0.5, 0.25, and 0.125 mm are created on the die with the corresponding pulsation frequencies of 5, 10, and 20 Hz. Finite element simulations are carried out using material model of dual phase (DP600) steel, that is one of the most widely used materials in automobile industry, in order to improve crash safety and fuel economy. Results obtained with press ram pulsation are compared with results for the conventional press ram motion and significant effect of proposed method is demonstrated