EDM simulation: finite element-based calculation of deformation, microstructure and residual stresses

A finite element-based model for the electric discharge machining (EDM) process is presented. The model uses process parameters such as power input, pulse duration, etc., to predict the transient temperature distribution, liquid- and solid-state material transformation, and residual stresses that are induced in the workpiece as a result of a single-pulse discharge. An attractive feature of the model is its ability to predict the shape of the crater that is formed as a result of the material removal. The model has been validated using experimental data, wherever possible. Extending the model to simulate the effects of multiple pulses will be undertaken in the near future.