Electro-Thermal Modeling for the Prediction of Surface Roughness in μ-EDM Using Finite Element Method

Micro-Electric Discharge Machining (μ-EDM) has been successfully employed for the production of miniaturized products and components. This machining process involves several disciplines of science and engineering in its theory. Therefore, the development of an accurate model for μ-EDM process is still a key issue due to its complex nature. In this paper, a model based on electro-thermal theory has been developed and solved using finite element method (FEM). This model is used for finding temperature distribution in the workpiece which is further used for determination of surface roughness during μ-EDM process. In order to simulate the realistic complex conditions, the model is developed accounting Gaussian heat flux distribution, temperature dependent thermal properties of workpiece material, phase change etc. Therefore, it is apparent that the developed model can be reliably used for the prediction of surface roughness in close conformity to the actual process. The predicted results can be used to determine the surface integrity of the machined surface.