ME -338 Manufacturing process II

Project : Modeling of wire erosion in EDM process

TA guide- Kamlesh Joshi
Team members:
-Aravind Somasundaram (120020012)
-Abhishek (120100072)
- Durga Prasad (120100063)
-Himanshu (

Abstract
Wire electron discharge machining (EDM) is a thermal process in which the electrodes
experience an intense local heating in the vicinity of the ionized channel. Removal of wire
material leads to its rupture. The two factors which are responsible for wire wear are reduction
of tensile strength of the material of the wire at elevated temperatures and reduction in
effective area of wire due to crater formation. In this project we aim to model parameters that
affect wire erosion such as three dimensional transient temperatures and crater formation. We
intend to make the model in matlab.
The three-dimensional transient temperature distribution in the vicinity of the plasma channel
during a single discharge period in the electrical discharge machining process is determined by
an explicit finite-difference model. The effect of a single spark is simulated by a variable heat
flux boundary condition that part of the circumference where the discharge channel interacts
with the wire and the governing heat conduction equation is solved by a finite difference
scheme. The heat-flux value is calculated from the radius of the time-dependent discharge
channel and the input power. The crater shapes are modeled from the temperature distribution
model.