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Advances in Materials Science and Engineering
Volume 2017, Article ID 8408793, 23 pages
Research Article

Study on the Gap Flow Simulation in EDM Small Hole Machining with Ti Alloy

School of Mechanical Engineering, Dalian Jiaotong University, Dalian 116028, China

Correspondence should be addressed to Wenchao Zhang; moc.liamg@525muart

Received 10 July 2016; Accepted 30 January 2017; Published 28 June 2017

Academic Editor: Gianfranco Palumbo

Copyright © 2017 Shengfang Zhang et al. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.


In electrical discharge machining (EDM) process, the debris removed from electrode material strongly affects the machining efficiency and accuracy, especially for the deep small hole machining process. In case of Ti alloy, the debris movement and removal process in gap flow between electrodes for small hole EDM process is studied in this paper. Based on the solid-liquid two-phase flow equation, the mathematical model on the gap flow field with flushing and self-adaptive disturbation is developed. In our 3D simulation process, the count of debris increases with number of EDM discharge cycles, and the disturbation generated by the movement of self-adaptive tool in the gap flow is considered. The methods of smoothing and remeshing are also applied in the modeling process to enable a movable tool. Under different depth, flushing velocity, and tool diameter, the distribution of velocity field, pressure field of gap flow, and debris movement are analyzed. The statistical study of debris distribution under different machining conditions is also carried out. Finally, a series of experiments are conducted on a self-made machine to verify the 3D simulation model. The experiment results show the burn mark at hole bottom and the tapered wall, which corresponds well with the simulating conclusion.