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A Modeling and Simulation Method for Preliminary Design of an Electro-Variable Displacement Pump

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Modeling of EDM Process Flushing Mechanism.

Timur Rizovich Ablyaz¹, Evgeny Sergeevich Shlykov¹, Karim Ravilevich Muratov¹

¹Department of Mechanical Engineering, Perm National Research Polytechnic University, Perm 614000, Russia.

Materials (Basel, Switzerland)

|June 10, 2023

Summary

Optimizing flushing conditions in electrical discharge machining (EDM) of titanium VT6 is crucial. A 15° nozzle angle enhances machining performance by preventing debris buildup and tool wear.

Keywords:

electrical discharge machining flushing sludge functionalmaterial titanium VT6

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Area of Science:

Materials Science
Manufacturing Engineering
Tribology

Background:

Titanium alloys like VT6 are vital in aerospace and medical industries.
Plasma cladding offers unique material properties but poses machining challenges.
Electrical Discharge Machining (EDM) is a non-traditional method for hard-to-machine materials.

Purpose of the Study:

To determine optimal flushing conditions for EDM of plasma-clad titanium VT6.
To analyze the impact of nozzle angle on flushing efficiency and machining performance.
To validate simulation results with experimental data.

Main Methods:

Theoretical analysis using ANSYS CFX 20.1 software for fluid flow dynamics.
Experimental validation of simulated flushing conditions.
Machining trials on titanium VT6 using copper electrode tools.

Main Results:

Turbulent fluid flow at 45° and 75° nozzle angles negatively impacts flushing quality and EDM performance for depths ≥10 mm.
A 15° nozzle angle relative to the tool axis optimizes flushing and enhances machining performance.
Incorrect flushing leads to sludge accumulation, short circuits, tool wear, and reduced surface quality and productivity.

Conclusions:

Optimal flushing is critical for stable and efficient EDM of deep holes in titanium VT6.
A 15° nozzle angle significantly improves the EDM process by minimizing debris and tool wear.
The study provides a validated approach for optimizing EDM parameters for advanced materials.