Numerical Study of Heat Transfer Effect of Wire EDM on P91, …€¦ · Abhishek Mishra BARC Dr....
Transcript of Numerical Study of Heat Transfer Effect of Wire EDM on P91, …€¦ · Abhishek Mishra BARC Dr....
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Numerical Study of Heat Transfer Effect of Wire EDM on P91, SS304, Al
1050 using COMSOL Multiphysics
S. Bhattacharya Director RPD,BARCAbhishek Mishra BARCDr. G.K.Dey RRF, BARCDr. Vivekanand Kain BARC
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WIRE ELECTRIC DISCHARGE MACHINING
➢ Wire Electric dischargemachining (WEDM) is a nonconventional machiningprocess.
➢It is an electro –thermal sparkerosion process which erodesmaterial using hightemperature spark
➢Spark is generated betweenthe two electrodes separatedby a dielectric medium likedemineralised water
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➢High voltage imparted to the electrodes causes breakdown of dielectric leading to generation of discharge.
➢High temperature spark melts the work piece material and molten material is eroded by the flushing jet of dielectric.➢The eroded material forms crater and affects the surface roughness of the machined surface
WIRE ELECTRIC DISCHARGE MACHINING
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NUMERICAL MODELING
➢ COMSOL 5.4 is used to model the WEDM process
➢ Size of crater formed after the erosion is estimated for SS304, AL1050, P91 steel
➢ Heat transfer module with phase change is used to model the heat transfer process occurring in WEDM process
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➢Heat conduction in the work piece is modelled using Fourier heat conduction model
➢A space dependent Gaussian heat flux of the order of 1011 W/m2 is applied on the work piece
➢To model the pulsed heat flux event module of COMSOL Multiphysics is used
➢ Temperature dependent property of the material is taken into consideration
➢The numerical results were verified with the actual crater sizes obtained by Scanning Electron Microscope images of the machined surface
NUMERICAL MODELING
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FOURIER HEAT CONDUCTION MODEL
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Temperature distribution on P91 work piece after spark is off
25µm
P91 Steel
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10µm
SEM image of machined surface of P91showing craters
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Temperature distribution on SS 304 work piece after spark is off
35µm
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20µm
SEM image of machined surface of SS showing craters
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15µm
Temperature distribution on AL1050 work piece after spark is off
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20µm
SEM image of machined surface of Al1050 showing craters
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Thank you