Numerical Simulation of Magnetic Field-Assisted Material Removal in Micro-EDM

In the present paper, a two dimensional numerical model has been developed using the finite element method (FEM) for predicting the material removal mechanism in micro EDM process in single spark with the assistance of magnetic field. The work piece material selected for the present study is grade 5 titanium material. The model developed by not considering magnetic field, first calculates the temperature distribution in the work piece material using the commercial software ANSYS. The crater shape is developed using the simulated temperature profiles to estimate the volume of material removed in a single spark, by considering the melting point and vaporization temperature. The model has been validated by comparing the theoretical MRR with the experimental results which is already established. The use of magnetic field which can provide an additional Lorentz force in the melt pool could aid in ejection of material from the discharge crater, thereby improving MRR. This concept is established through the coupling of magnetic and structural fields.