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Thermal Modeling and Structural Analysis in Wire EDM Process for a 3D Model

Wire EDM is one of the most non conventional machining processes used for cutting of different types of complex materials. Copper material in wire EDM has a wide application in several industries but its thermal and structural analysis in wire EDM has challenged the authors to model the work-piece and tools accurately using the software. The present work deals with the design of a 3 dimensional model of a work-piece material made of copper. The objective of the present work is to analyse the temperature, total heat flux and equivalent stress of the work-piece material using finite element analysis in ANSYS software. In the current work, a 3D model was designed with the Steady state thermal analysis and it was designed with the available experimental data using ANSYS workbench. The temperature and the total heat flux were calculated using this analysis. Another analysis is performed using Static structural to calculate the equivalent stress generated in the work-piece material using ANSYS. The model was developed for single spark only. Automated type of meshing and axi-symmetric type of geometry are considered for this experiment. The wire part is neglected and all the analysis is made on the work-piece only. XRD analysis is also performed on the work-piece material to know the crystallinity of the compound. Mesh Convergence test was also performed to determine the optimum solution for the requisite mesh. Finally the model was designed and various graphs were plotted for the temperature, total heat flux and equivalent stress of the material.