The Impact of FEM Modeling Parameters on the Computed Thermo-Mechanical Behavior of SLA Copper Shelled Electrodes

The Impact of FEM Modeling Parameters on the Computed Thermo-Mechanical Behavior of SLA Copper Shelled Electrodes

Vassilios Iakovakis (Technological Educational Institute of Larissa, Greece), John Kechagias (Technological Educational Institute of Larissa, Greece), George Petropoulos (University of Thessaly, Greece) and Stergios Maropoulos (Technological Educational Institute of West Macedonia, Greece)
DOI: 10.4018/ijmmme.2011070103
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In this study, the authors use the finite element method to model and analyse a cylindrical copper shelled SLA electrode for EDM operations, which is investigated experimentally in literature. A uniform silver paint thickness and copper shell thickness is assumed around the SLA epoxy core. In the experiment, 2-D analysis was used due to the axissymmetric shape, and steady state and transient die sink EDMing simulations were followed. Modelling parameters are varied and their impact on the resulting temperature and stress fields is evaluated. The intermittent nature of the electrode thermal loading is also simulated with FEM transient analysis. It is shown that, using the finite element method, the influence of the copper shelled SLA electrode manufacturing and EDM-process parameters can be studied.
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Thermomechanical Simulations

As aforementioned, the thermal load generated during EDM (Figure 1) causes failure of the SLA electrodes. The very unlike response to heat of the resin core and the copper shell is the main reason for most failure modes (Arthur & Dickens, 1998). This is justified as it is well known that heat affects distortions, which depend on the physical properties of the structure subjected to the thermal load. The knowledge of the influence of the various parameters on the electrode behaviour can help in the development of SLA electrodes, which show acceptable wear when loaded with higher currents. Since experimental research is difficult, the Finite Element Method (FEM) can be used to approach the temperature and stress distributions in the electrode.

Figure 1.

Periodic discharges


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