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T.C. ALTINBAS UNIVERSITY Institute of Graduate Studies Mechanical Engineering T.C. ALTINBAS UNIVERSITY Institute of Graduate Studies Mechanical Engineering Numerical Investigation of Transient Thermal and Structural Analysis in Electrical Discharge Machining (EDM) Process by Using Finite Element Method Mohammed Hatem Nassr AL-AZZAWI Master of Science Supervisor Asst. Prof. Dr. Suleyman BASTURK Istanbul, 2020 Numerical Investigation of Transient Thermal and Structural Analysis in Electrical Discharge Machining (EDM) Process by Using Finite Element Method by Mohammed Hatem Nassr AL-AZZAWI Mechanical Engineering Submitted to the Institute of Graduate Studies in partial fulfillment of the requirements for the degree of Master of Science ALTINBAŞ UNIVERSITY 2020 The thesis titled “Numerical Investigation of Transient Thermal and Structural Analysis in Electrical Discharge Machining (EDM) Process by Using Finite Element Method ” prepared and presented by “Mohammed Hatem Nassr AL-AZZAWI” was accepted as a Master of Science Thesis in Mechanical Engineering. Asst. Prof. Dr. Suleyman BASTURK Co-Supervisor Supervisor Thesis Defense Jury Members: Prof. Dr. Osman Ergüven VATANDAŞ Faculty of Engineering and Architecture, Istanbul Gelişim University __________________ Asst. Prof. Dr. Süleyman BAŞTÜRK Faculty of Engineering and Natural Science, Altınbaş University __________________ Asst. Prof. Dr.İbrahim KOÇ Faculty of Engineering and Natural Science, Altınbaş University __________________ I certify that this thesis satisfies all the requirements as a thesis for the degree of Master of Science. Approval Date of Institute of Graduate Studies: ____/____/____ iii I hereby declare that all information in this document has been obtained and presented in accordance with academic rules and ethical conduct. I also declare that, as required by these rules and conduct, I have fully cited and referenced all material and results that are not original to this work. Mohammed Hatem Nassr AL-AZZAWI iv DEDICATION I would like to dedicate this work to my first teacher, my mother, my first supporter and role model, and my companion throughout the journey and my father and my brothers. Without you, this dream would never come true and I give this thesis in a form of appreciation and I may ask Allah to accept this work. v ACKNOWLEDGEMENTS I might want to offer my thanks to every one of the individuals who have upheld me all through the regularly extended periods of this voyage. I might want to thank my advisor, Asst. Prof. Dr. Suleyman BASTURK for being my compass notwithstanding, when I believed I was lost and being in extraordinary part in charge of the zenith of this work. I might likewise want to thank my supervisor for his supportive exhortation, which incredibly enhanced the nature of this work. Finally, I thank this institution for hosting me during these years, securely earning its place as my home. I am very thankful to my mom and dad, whose values and education motivate me to keep asking questions; to my siblings and family for their infinitely appreciated love and to my country which, although inanimate, keeps me anchored and offers me an example of resiliency. vi ABSTRACT Numerical Investigation of Transient Thermal and Structural Analysis in Electrical Discharge Machining (EDM) Process by Using Finite Element Method Mohammed Hatem Nassr AL-AZZAWI M.Sc., Mechanical Engineering, Altinbaş University, Supervisor: Asst. Prof. Dr. Suleyman BASTURK Date: November 2020 Pages: (67) Electrical discharge machining (EDM) can be categorized as unconventional processes for removing materials. EDM is widely used in many applications such as molding and dies fabrication. This thesis research deals with the heat and stress analysis of the production of the EDM machining of titanium and stainless steel sheets. The effect of undercutting velocity on sheet stresses as well as thermal properties by using ANSYS (Transient Thermal and Transient Structural) software has been investigated. The analysis set was achieved with 10 steps with 30, 20 and 10 seconds under the surrounding temperature of 27oC as well as the initial temperature of the electrode and the workpiece as 27oC. Gaussian heat flux profile with heat transfer by conduction, convection, and radiation were modeled. The electrode moves in the x-direction with three various velocity such as 0.667 mm/s, 1 mm/s, and 2 mm/s in the middle of the workpiece. Heat flux distribution is more operative where the heat was distributed quickly, and this will help to protect the electrode. The maximum temperature in the case of the titanium sheet is more than the stainless steel sheet. The equivalent mechanical stresses that resulted from thermal stresses are studied and the distribution of equivalent stresses was performed with the second velocity where the residual stress is small because the solidification layer melts thinly. Keywords: Temperature, stresses, EDM, titanium, heat flux, workpiece. vii Özet Sonlu Elemanlar Yöntemi Kullanarak Elektro Erozyon (EDM) İşleminin Geçici Termal ve Yapısal Analizinin Sayısal İncelenmesi Elektro erozyon ile işleme işlemi (EDM), malzemelerin şekillendirilmesi için geleneksel olmayan işlemlerden biri olarak kategorize edilebilir. EDM işlemi, kalıplama ve kalıp üretimi gibi birçok uygulamada yaygın olarak kullanılmaktadır. Bu tez çalışmasında, titanyum levhanın EDM ile işlenmesi esnasında oluşan ısı ve stres analizi yapılmıştır. ANSYS (Geçici Termal ve Geçici Yapısal) Programı kullanımı ile kesme hızının alt tabaka kesme gerilmeleri üzerindeki etkileri ve termal özellikleri incelenmiştir. Analiz seti, 30, 20 ve 10 saniyelik çevre sıcaklığı 27 oC ile 10 aşamada gerçekleştirilmiştir. İletim, konveksiyon ve radyasyon yoluyla ısı transferi ile Gauss ısı akısı profili modellenmiştir. Elektrot, iş parçasının ortasında üç farklı hızda 0.667 mm/s, 1 mm/s, ve 2mm/s ile x ekseni yönünde hareket etmiştir. Elektrot ve iş parçasının başlangıç sıcaklığı 27 oC'dir. Isı akısı dağılımı, ısının hızlı bir şekilde dağıtıldığı yerde daha etkilidir ve bu, elektrotun korunmasına yardımcı olmaktadır. Termal gerilmelerden kaynaklanan eşdeğer mekanik gerilmeler incelenmiş ve eşdeğer gerilmelerin dağılımının yeniden katılaştırma tabakasının çok az erimesinden dolayı artık gerilmenin küçük olduğu ikinci hız ile gerçekleştirilmiştir. Anahtar Kelimeler: Sıcaklık, gerilmeler, EDM, titanyum, ısı akısı, iş parçası. viii TABLE OF CONTENTS Pages ABSTRACT ................................................................................................................................. vii LIST OF FIGURES .................................................................................................................... xii LIST OF ABBREVIATIONS ................................................................................................... xiv LIST OF SYMBOLS .................................................................................................................. xv 1. INTRODUCTION ............................................................................................................... 1 1.1 MACHINING .................................................................................................................... 1 1.2 EDM CUTTING ................................................................................................................ 1 1.2.1 Advantages and Disadvantages of EDM ...................................................................... 2 1.3 EDM CUTTING TYPES .................................................................................................. 3 1.3.1 Die-sink EDM ............................................................................................................... 3 1.3.2 Wire-cut EDM .............................................................................................................. 4 1.3.3 Applications .................................................................................................................. 6 1.3.3.1 Prototype production............................................................................................... 6 1.3.3.2 Small hole drilling .................................................................................................. 7 1.3.3.3 Metal disintegration machining .............................................................................. 8 1.4 MATERIALS OF ELECTRODE ...................................................................................... 8 1.4.1 Types ............................................................................................................................ 9 1.4.2 Specifications .............................................................................................................. 10 1.5 OVERVIEW OF PROCESS MODEL DEVELOPMENT .............................................. 10 2. LITERATURE REVIEW ................................................................................................. 12 2.1 INTRODUCTION ........................................................................................................... 12 2.2 THE NOVELTY OF THE STUDY ................................................................................ 21 3. NUMERICAL STUDY ..................................................................................................... 22 3.1 MATERIAL AND GEOMETRY SELECTION ............................................................. 23 3.2 NUMERICAL METHOD ............................................................................................... 26 ix 3.2.1 Physical Model ..........................................................................................................
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