Simulation of Die-Sinking EDM by Discharge Location Searching Algorithm

This paper deals with simulation of workpiece geometry eroded by a die-sinking EDM using a newly developed simulation algorithm for faithful imitation of the actual phenomena which are occurring in the gap. The algorithm is a simple repetition of the procedure which is comprised of: (1) determining the next discharge location where the dielectric breakdown strength is lowest, (2) removing the tool and workpiece electrodes, (3) distributing the debris particles, and (4) feeding the tool electrode. The simulation takes into account a variety of influential factors such as tool electrode wear, gap width distribution, curvature and inclination of the tool electrode, and debris particle concentration, all of which affect each other in a very complex manner. The simulation results for the geometries of the tool electrode and the workpiece after machining and for the gap width distribution agree well with the experimental results for machining of a flat and square surface.